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MLITEMP computer program is design software tool utilizing empirical equations to predict damage and thermal effects of impacts of hypervelocity particles on spacecraft. Three different techniques used: "inverse-R" prediction, polynomial-function prediction, and nondimensional-parameter prediction. Written in BASIC.
This handbook reviews the analysis of structural damage on spacecraft due to hypervelocity impacts by meteoroid and space debris. These impacts can potentially cause structural damage to a Space Station module wall. This damage ranges from craters, bulges, minor penetrations, and spall to critical damage associated with a large hole, or even rupture. The analysis of damage depends on a variety of assumptions and the area of most concern is at a velocity beyond well controlled laboratory capability. In the analysis of critical damage, one of the key questions is how much momentum can actually be transfered to the pressure vessel wall. When penetration occurs without maximum bulging at high velocity and obliquities (if less momentum is deposited in the rear wall), then large tears and rupture may be avoided. In analysis of rupture effects of cylindrical geometry, biaxial loading, bending of the crack, a central hole strain rate and R-curve effects are discussed.
It is necessary to integrate a wide variety of technical disciplines to provide an analysis of structural damage to a spacecraft due to hypervelocity impact. There are many uncertainties, and more detailed investigation is warranted, in each technical discipline. However, a total picture of the debris and meteoroid hazard is required to support manned spaceflight in general, and the international Space Station in particular. In the performance of this contract, besides producing a handbook, research and development was conducted in several different areas. The contract was broken into six separate tasks. Each task objectives and accomplishments will be reviewed in the following sections. The Handbook and separate task reports are contained as attachments to the final report. The final section summarizes all of the recommendations coming out of this study. The analyses and comments are general design guidelines and not necessarily applicable to final Space Station designs since several configuration and detailed design changes were being made during the course of this contract. Rather, the analyses and comments may indicate either a point-in-time concept analysis, available test data, or desirable protection goals, not hindered by the design and operation constraints faced by Space Station designers.
A portion of the contract NAS8-38856, 'Structural Damage Prediction and Analysis for Hypervelocity Impacts,' from NASA Marshall Space Flight Center (MSFC), included consulting which was to be documented in the final report. This attachment to the final report contains memos produced as part of that consulting.
Small radius leading edges and nosetips were utilized to minimize wave drag in early hypervelocity vehicle concepts until further analysis demonstrated that extreme aerothermodynamic heating would cause severe ablation or blunting of the available thermal protection system materials. Recent studies indicate that ultrahigh temperature ceramic (UHTC) materials are shape stable at temperatures approaching 3033 K and will be available for use as sharp UHTC leading edge components in the near future. Aerothermal performance constraints for sharp components made from these materials are presented in this work to demonstrate the effects of convective blocking, surface catalycity, surface emissivity, and rarefied flow effects on steady state operation at altitudes from sea level to 90 km. These components are capable of steady state operation at velocities up to 7.9 km/s at attitudes near 90 km.
Small radius leading edges and nosetips were used to minimize wave drag in early hypervelocity vehicle concepts until further analysis demonstrated that extreme aerothermodynamic heating blunted the available thermal protection system materials. Recent studies indicate that ultra-high temperature composite (UHTC) materials are shape stable at temperatures approaching 3033 K and will be available for use as sharp leading edge components in the near future. Steady-state aerothermal performance constraints for UHTC components are presented in this paper to identify their non-ablating operational capability at altitudes from sea level to 90 km. An integrated design tool was developed to estimate these constraints. The tool couples aerothermodynamic heating with material response using commercial finite element analysis software and is capable of both steady-state and transient analysis. Performance during entry is analyzed by transient thermal analysis along the trajectory. The thermal load condition from the transient thermal analysis is used to estimate thermal stress. Applying the tool to UHTC materials shows that steady-state, non-ablating operation of a HfB2/SiC(A-7) (A-7) component is possible at velocities approaching Earth's circular orbital velocity of 7.9 km/s at altitudes approaching 70 km.
Composite and honeycomb panels are commonly used for spacecraft structural components. The impact test results and analysis of six different composite and honeycomb combinations for use on the advanced X-ray astrophysics facility (AXAF) are reported. The AXAF consists of an X-ray telescope and the associated detecting devices attached to an octagonal spacecraft with an internal propulsion system. The spacecraft's structural panels and optical bench are made of two different graphite fiber reinforced polyimides or composite panels bonded to either side of an aluminum honeycomb. The instrument is required to have at least a 0.92 probability of no failure of any of the critical elements due to meteoroids and debris. In relation to the no-failure probability determination in its low earth orbit environment, hypervelocity impact testing was performed to determine the ballistic limit range and the extent of damage due to impact. The test results for a power and signal cable bundle located behind a panel are presented. Tests planned for a multilayer insulation (MLI) blanket and four types of cable bundles are discussed.
In the hypersonic flight regime, the air-breathing supersonic combustion ramjet (scramjet) has been shown to be a viable propulsion system. The current designs of scramjet engines provide performance benefits only up to a Mach number of 14. Performance losses increase rapidly as the Mach number increases. To extend the applicability of scram'jets beyond Mach 14, research is being conducted in the area of inlet and wave drag reduction, skin-friction and heat-transfer reduction, nozzle loss minimization, low-loss mixing, and combustion enhancement. For high Mach number applications, hydrogen is the obvious fuel choice because of its high energy content per unit mass in comparison with conventional fuels. These flight conditions require engines to operate at supersonic internal velocities, high combustor temperatures, and low static pressures. The high static temperature condition enhances the production of radicals such as H and OH, and the low-pressure condition slows the reaction rates, particularly the recombination reactions. High-temperature and low-pressure constraints, in combination with a small residence time, result in a radical-rich exhaust gas mixture exiting the combustor. At high Mach number conditions (due to low residence time), H and OH do not have enough time to recombine ; thus, a significant amount of energy is lost as these high-energy free radical are exhausted. The objective of the present study is to conduct a flowfield analysis for a typical nozzle geometry for NASP-type vehicle to assess for thrust enhancement in hypervelocity nozzles by substituting small amount of phosphine for hydrogen.
It is shown that for any electromagnetic accelerator which employs an electromagnetic force for driving the projectile and uses the projectile as the heat sink for the energy dissipated in it by ohmic heating, the maximum velocity attainable without melting is a function of the mass of the projectile. Therefore, for hypervelocities a large projectile mass is required and thus a power supply of very large capacity is necessary. It is shown that the only means for reducing the power requirement is maximizing the gradient of the mutual inductance. In the scheme of the sliding-coil accelerator investigated herein, the gradient of the mutual inductance is continuously maintained at a high value. It is also shown that for minimum length of the accelerator, the current must be kept constant despite the rise in induced voltage during acceleration. The use of a capacitor bank as an energy source with the condition that the current be kept constant is investigated. Experiments at low velocities are described.
Gun development efforts to increase the launching capabilities of the NASA Ames 0.5-inch two-stage light-gas gun have been investigated. A gun performance simulation code was used to guide initial parametric variations and hardware modifications, in order to increase the projectile impact velocity capability to 8 km/s, while maintaining acceptable levels of gun barrel erosion and gun component stresses. Concurrent with this facility development effort, a hypervelocity impact testing series in support of the X-33/RLV program was performed in collaboration with Rockwell International. Specifically, advanced thermal protection system materials were impacted with aluminum spheres to simulate impacts with on-orbit space debris. Materials tested included AETB-8, AETB-12, AETB-20, and SIRCA-25 tiles, tailorable advanced blanket insulation (TABI), and high temperature AFRSI (HTA). The ballistic limit for several Thermal Protection System (TPS) configurations was investigated to determine particle sizes which cause threshold TPS/structure penetration. Crater depth in tiles was measured as a function of impact particle size. The relationship between coating type and crater morphology was also explored. Data obtained during this test series was used to perform a preliminary analysis of the risks to a typical orbital vehicle from the meteoroid and space debris environment.
Chemical and thermal nonequilibrium phenomena are studied in the stagnation region of a hypervelocity blunt body. This investigation is motivated by the need to predict the heat-transfer rate to the leading edge of aeromaneuvering orbital transfer vehicles. Flight speeds of approximately 10 km/s at altitudes of approximately 80 km are considered for body radii of 1-50 cm. The analysis is based on continuum theory and is applicable to the viscous and incipient merged layer regimes of rarefied flow. A two-species, two-temperature gas model is assumed. Comparisons are made with previous theories, experimental data, and results based on the thermodynamic equilibrium assumption. The equation accounting for vibrational nonequilibrium is presented and its effects on flow properties are discussed. Parameters requiring further investigation are identified. Preliminary results indicate that the inclusion of vibrational relaxation has little effect on the heat-transfer rate for a fully catalytic surface. However, vibrational nonequilibrium may increase the heat-transfer rate to a noncatalytic surface, depending on the degree of nonequilibrium.
An improved hybrid particle-finite element method has been developed for hypervelocity impact simulation. The method combines the general contact-impact capabilities of particle codes with the true Lagrangian kinematics of large strain finite element formulations. Unlike some alternative schemes which couple Lagrangian finite element models with smooth particle hydrodynamics, the present formulation makes no use of slidelines or penalty forces. The method has been implemented in a parallel, three dimensional computer code. Simulations of three dimensional orbital debris impact problems using this parallel hybrid particle-finite element code, show good agreement with experiment and good speedup in parallel computation. The simulations included single and multi-plate shields as well as aluminum and composite shielding materials. at an impact velocity of eleven kilometers per second.
The Hypervelocity Free-Flight Aerodynamic Facility, located at Ames Research Center, is NASA's only aeroballistic facility. During 1997, its model imaging and time history recording systems were the focus of a major refurbishment effort. Specifically the model detection, spark gap (light source); Kerr cell (high speed shuttering); and interval timer sub-systems were inspected, repaired, modified or replaced as required. These refurbishment efforts have fully restored the HFFAF's capabilities to a much better condition, comparable to what it was 15 years ago. Details of this refurbishment effort along with a brief discussion of future upgrade plans are presented.
A facility has been developed and put into operation to determine the feasibility of obtaining hypervelocity impact data by using the relative velocities of two projectiles. The facility utilizes the technique of firing a target toward an oncoming high-velocity projectile so that the impact velocity is equal to the sum of the projectile velocity and the target velocity. A 37-millimeter powder gun is utilized to accelerate the targets, and a specially designed 22-caliber light-gas gun accelerates the impacting projectiles. The light-gas gun is operated by detonating an explosive charge which permits it to be synchronized with the firing of the 37-millimeter gun. Impact velocities as great as 21,850 ft/sec have been obtained during development of the facility. After the oncoming projectiles impact the targets fired from the 37-millimeter gun, these targets are recovered by allowing them to impact into Celotex and soft wooden blocks. The craters formed in the targets then can be observed and measured. The results of several preliminary firings of the facility are included in this report.
The ability to capture projectiles intact at hypervelocities opens new applications in science and technology that would either not be possible or would be very costly by other means. This capability has been demonstrated in the laboratory for aluminum projectiles of 1.6 mm diameter, captured at 6 km/s, in one unmelted piece, and retaining up to 95% of the original mass. Furthermore, capture was accomplished passively using microcellular underdense polymer foam. Another advantage of capturing projectiles in an underdense medium is the ability of such a medium to preserve a record of the projectile's original velocity components of speed and direction. A survey of these experimental results is described in terms of a dozen parameters which characterize the amount of capture and the effect on the projectile due to different capture media.
A series of experiments has been conducted in the NASA HYPULSE Expansion Tube, in both CO2 and air test gases, in order to obtain data for comparison with computational results and to assess the capability for performing hypervelocity heat-transfer studies in this facility. Heat-transfer measurements were made in both test gases on 70 deg sphere-cone models and on hemisphere models of various radii. HYPULSE freestream flow conditions in these test gases were found to be repeatable to within 3-10%, and aerothermodynamic test times of 150 microsec in CO2 and 125 microsec in air were identified. Heat-transfer measurement uncertainty was estimated to be 10-15%. Comparisons were made with computational results from the non-equilibrium Navier-Stokes solver NEQ2D. Measured and computed heat-transfer rates agreed to within 10% on the hemispheres and on the sphere-cone forebodies, and to within 10% in CO2 and 25% in air on the afterbodies and stings of the sphere-cone models.
An improved hybrid particle-finite element method has been developed for the simulation of hypervelocity impact problems. Unlike alternative methods, the revised formulation computes the density without reference to any kernel or interpolation functions, for either the density or the rate of dilatation. This simplifies the state space model and leads to a significant reduction in computational cost. The improved method introduces internal energy variables as generalized coordinates in a new formulation of the thermomechanical Lagrange equations. Example problems show good agreement with exact solutions in one dimension and good agreement with experimental data in a three dimensional simulation.
Spacecraft operating in low earth orbit face a significant orbital debris impact hazard. Of particular concern, in the case of the Space Shuttle, are impacts on critical components of the thermal protection system. Recent research has formulated a new material model of reinforced carbon-carbon, for use in the analysis of hypervelocity impact effects on the Space Shuttle wing leading edge. The material model has been validated in simulations of published impact experiments and applied to model orbital debris impacts at velocities beyond the range of current experimental methods. The results suggest that momentum scaling may be used to extrapolate the available experimental data base, in order to predict the size of wing leading edge perforations at impact velocities as high as 13 km/s.