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At least 289 records · Page 16

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NASA NTRS1998

RSRM Nozzle Anomalous Throat Erosion Investigation Overview

In September, 1996, anomalous pocketing erosion was observed in the aft end of the throat ring of the nozzle of one of the reusable solid rocket motors (RSRM 56B) used on NASA's space transportation system (STS) mission 79. The RSRM throat ring is constructed of bias tape-wrapped carbon cloth/ phenolic (CCP) ablative material. A comprehensive investigation revealed necessary and sufficient conditions for occurrence of the pocketing event and provided rationale that the solid rocket motors for the subsequent mission, STS-80, were safe to fly. The nozzles of both of these motors also exhibited anomalous erosion similar to, but less extensive than that observed on STS-79. Subsequent to this flight, the investigation to identify both the specific causes and the corrective actions for elimination of the necessary and sufficient conditions for the pocketing erosion was intensified. A detailed fault tree approach was utilized to examine potential material and process contributors to the anomalous performance. The investigation involved extensive constituent and component material property testing, pedigree assessments, supplier audits, process audits, full scale processing test article fabrication and evaluation, thermal and thermostructural analyses, nondestructive evaluation, and material performance tests conducted using hot fire simulation in laboratory test beds and subscale and full scale solid rocket motor static test firings. This presentation will provide an over-view of the observed anomalous nozzle erosion and the comprehensive, fault-tree based investigation conducted to resolve this issue.

Clinton, R. G., Jr.↗

NASA NTRS1996

PICA Forebody Heatshield Qualification for the Stardust Discovery Class Mission

This paper presents the qualification of the light weight Phenolic Impregnated Carbon Ablators (PICA) as the forebody heatshield for the Stardust Discovery Class Mission. The Stardust spacecraft will be launched in early 1999 and fly by Comet Wild-2 to collect cometary and interstellar dust and return them back to earth in the Sample Return Capsule (SRC). This earth re-entry will be the fastest to date, at 12.6 km/s, and therefore requires a heatshield that can withstand very high heating rates and stagnation pressures, as well as provide the necessary insulation to the vehicle structure. The PICA material was developed as part of the Lightweight Ceramic Ablators program at NASA Ames Research Center, and was baselined as the forebody heatshield because of its low density and superior ablation and thermal performance at severe aerothermodynamic conditions. Under a Small Business Innovative Research (SBIR) program with NASA Ames, Fiber Materials, Inc. developed a process to manufacture a single-piece PICA heatshield for the forebody of the SRC, along with witness material for the fabrication of the test models. The test models were fabricated and instrumented by the staff of Lockheed Martin Astronautics in Denver, Colorado. Full body preliminary aerothermal CFD calculations were performed at NASA Ames to determine the heating and stagnation pressure conditions. The Heat shield sizing was also performed at NASA Ames by using a new material response code that accounts for the highly porous characteristics of the PICA material. The ablation and thermal performance of PICA was qualified in the NASA Ames Interaction Heating Arc Jet Facility. A total of 24 models and four test conditions were used to qualify PICA at the predicted peak heat flux, heat load, shear, and stagnation pressure conditions. Surface and in-depth temperatures were measured using optical pyrometers and thermocouples. Surface recession was measured by using a template and a height gage. Several models were tested to evaluate repair procedures, and two models were cold soaked in liquid nitrogen, prior th testing, to investigate the effect of the cold space environment on the performance of the material. In addition, material cored from a demonstration single-piece heatshield was tested to verify that the PICA process can be successfully completed on a large, complex heatshield shape.

Tran, Huy K.↗

NASA NTRS2002

NARC Rayon Replacement Program

This viewgraph presentation provides information on the search for a replacement product for the aerospace grade rayon formerly used in the reusable solid rocket motor (RSRM). The rayon used in RSRMs is no longer produced by the North American Rayon Corporation (NARC), though NASA has stockpiled rayon to be used until a suitable replacement is found to be used in the RSRM nozzle carbon cloth phenolic (CCP). The primary considerations are performance, process ability, variability, long term availability, and cost. The preference will be given to commercial off-the-shelf products as opposed to those which are custom made. The candidate materials have been tested in previous phases of this selection process, and Enka Textile Rayon has emerged as a possible fabric, though its availability is still in question.

Wilson, Kenneth P.↗

NASA NTRS2005

Performance of a Light-Weight Ablative Thermal Protection Material for the Stardust Mission Sample Return Capsule

New tests and analyses are reported that were carried out to resolve testing uncertainties in the original development and qualification of a lightweight ablative material used for the Stardust spacecraft forebody heat shield. These additional arcjet tests and analyses confirmed the ablative and thermal performance of low density Phenolic Impregnated Carbon Ablator (PICA) material used for the Stardust design. Testing was done under conditions that simulate the peak convective heating conditions (1200 W/cm2 and 0.5 atm) expected during Earth entry of the Stardust Sample Return Capsule. Test data and predictions from an ablative material response computer code for the in-depth temperatures were compared to guide iterative adjustment of material thermophysical properties used in the code so that the measured and predicted temperatures agreed. The PICA recession rates and maximum internal temperatures were satisfactorily predicted by the computer code with the revised properties. Predicted recession rates were also in acceptable agreement with measured rates for heating conditions 37% greater than the nominal peak heating rate of 1200 W/sq cm. The measured in-depth temperature response data show consistent temperature rise deviations that may be caused by an undocumented endothermic process within the PICA material that is not accurately modeled by the computer code. Predictions of the Stardust heat shield performance based on the present evaluation provide evidence that the maximum adhesive bondline temperature will be much lower than the maximum allowable of 250 C and an earlier design prediction. The re-evaluation also suggests that even with a 25 percent increase in peak heating rates, the total recession of the heat shield would be a small fraction of the as-designed thickness. These results give confidence in the Stardust heat shield design and confirm the potential of PICA material for use in new planetary probe and sample return applications.

Covington, M. A.↗

NASA NTRS2009

Analytical Predictions of Thermal Stress in the Stardust PICA Heatshield Under Reentry Flight Conditions

We performed finite element analyses on a model of the Phenolic Impregnated Carbon Ablator (PICA) heatshield from the Stardust sample return capsule (SRC) to predict the thermal stresses in the PICA material during reentry. The heatshield on the Stardust SRC was a 0.83 m sphere cone, fabricated from a single piece of 5.82 cm-thick PICA. The heatshield performed successfully during Earth reentry of the SRC in January 2006. Material response analyses of the full, axisymmetric PICA heatshield were run using the Two-Dimensional Implicit Ablation, Pyrolysis, and Thermal Response Program (TITAN). Peak surface temperatures were predicted to be 3385K, while the temperature at the PICA backface remained at the estimated initial cold-soak temperature of 278K. Surface recession and temperature distribution results from TITAN, at several points in the reentry trajectory, were mapped onto an axisymmetric finite element model of the heatshield. We used the finite element model to predict the thermal stresses in the PICA from differential thermal expansion. The predicted peak compressive stress in the PICA heatshield was 1.38 MPa. Although this level of stress exceeded the chosen design limit for compressive stresses in PICA tiles for the design of the Orion crew exploration vehicle heatshield, the Stardust heatshield exhibited no obvious mechanical failures from thermal stress. The analyses of the Stardust heatshield were used to assess and adjust the level of conservatism in the finite element analyses in support of the Orion heatshield design.

Squire, Thomas↗

NASA NTRS2009

Validation of PICA Ablation and Thermal-Response Model at Low Heat Flux

Phenolic Impregnated Carbon Ablator (PICA) was the forebody heatshield material on the Stardust sample-return capsule and is also a primary candidate material for the Mars Science Lander (MSL), the Orion Crew Module, and the SpaceX Dragon vehicle. As part of the heatshield qualification for Orion, physical and thermal properties of virgin and charred PICA were measured, and an ablation and thermal response model was developed. We validated the model by comparing it with recession and temperature data from stagnation arcjet tests conducted over a wide range of stagnation heat flux of 107 to 1102 W/sq cm. The effect of orthotropic thermal conductivity was evident in the thermal response of the arcjet models. In general, model predictions compared well with the data; however, the uncertainty of the recession prediction was greatest for heat fluxes below 200 W/sq cm. More recent MSL testing focused on the low heat flux regime of 45 to 250 W/sq cm. The new results confirm the recession uncertainty, especially for pressures below 6 kPa. In this work we focus on improving the model predictions for MSL and Orion tests below 250 W/sq cm.

Milos, Frank S.↗

NASA NTRS2009

Arcjet Tests of Different Gap-Filler Options for the Orion PICA Heatshield

PICA (Phenolic Infiltrated Carbon Ablator) is one of the candidate thermal protection materials for the Orion vehicle. Because PICA is fabricated in blocks, gaps exist between the blocks, similar to the individual ceramic tiles of the Shuttle thermal protection system. The results of this work focus on arcjet test results of different gap-filler options for PICA, performed as part of the Orion TPS Advanced Development Project. The arcjet tests were performed at NASA Ames Research Center on stagnation models 4 inches in diameter at conditions representative of Orion flight conditions for both Lunar and Low Earth Orbit return. Performance of gap-filler options was evaluated based on the extent of backface temperature change, as compared to PICA without gaps, and on the extent of flow penetration into the gap, evident from the gap opening and widening.

Skokova, Kristina↗

NASA NTRS2010

X-Ray Computed Tomography Inspection of the Stardust Heat Shield

The "Stardust" heat shield, composed of a PICA (Phenolic Impregnated Carbon Ablator) Thermal Protection System (TPS), bonded to a composite aeroshell, contains important features which chronicle its time in space as well as re-entry. To guide the further study of the Stardust heat shield, NASA reviewed a number of techniques for inspection of the article. The goals of the inspection were: 1) to establish the material characteristics of the shield and shield components, 2) record the dimensions of shield components and assembly as compared with the pre-flight condition, 3) provide flight infonnation for validation and verification of the FIAT ablation code and PICA material property model and 4) through the evaluation of the shield material provide input to future missions which employ similar materials. Industrial X-Ray Computed Tomography (CT) is a 3D inspection technology which can provide infonnation on material integrity, material properties (density) and dimensional measurements of the heat shield components. Computed tomographic volumetric inspections can generate a dimensionally correct, quantitatively accurate volume of the shield assembly. Because of the capabilities offered by X-ray CT, NASA chose to use this method to evaluate the Stardust heat shield. Personnel at NASA Johnson Space Center (JSC) and Lawrence Livermore National Labs (LLNL) recently performed a full scan of the Stardust heat shield using a newly installed X-ray CT system at JSC. This paper briefly discusses the technology used and then presents the following results: 1. CT scans derived dimensions and their comparisons with as-built dimensions anchored with data obtained from samples cut from the heat shield; 2. Measured density variation, char layer thickness, recession and bond line (the adhesive layer between the PICA and the aeroshell) integrity; 3. FIAT predicted recession, density and char layer profiles as well as bondline temperatures Finally suggestions are made as to future uses of this technology as a tool for non-destructively inspecting and verifying both pre and post flight heat shields.

McNamara, Karen M.↗

NASA NTRS2010

Multidimensional Tests of Thermal Protection Materials in the Arcjet Test Facility

Many thermal protection system materials used for spacecraft heatshields have anisotropic thermal properties, causing them to display significantly different thermal characteristics in different directions, when subjected to a heating environment during flight or arcjet tests. This paper investigates the effects of sidewall heating coupled with anisotropic thermal properties of thermal protection materials in the arcjet environment. Phenolic Impregnated Carbon Ablator (PICA) and LI-2200 materials (the insulation material of Shuttle tiles) were used for this study. First, conduction-based thermal response simulations were carried out, using the Marc.Mentat finite element solver, to study the effects of sidewall heating on PICA arcjet coupons. The simulation showed that sidewall heating plays a significant role in thermal response of these models. Arcjet tests at the Aerodynamic Heating Facility (AHF) at NASA Ames Research Center were performed later on instrumented coupons to obtain temperature history at sidewall and various radial locations. The details of instrumentation and experimental technique are the prime focus of this paper. The results obtained from testing confirmed that sidewall heating plays a significant role in thermal response of these models. The test results were later used to verify the two-dimensional ablation, thermal response, and sizing program, TITAN. The test data and model predictions were found to be in excellent agreement

Agrawal, Parul↗

NASA NTRS2010

Validation of a Three-Dimensional Ablation and Thermal Response Simulation Code

The 3dFIAT code simulates pyrolysis, ablation, and shape change of thermal protection materials and systems in three dimensions. The governing equations, which include energy conservation, a three-component decomposition model, and a surface energy balance, are solved with a moving grid system to simulate the shape change due to surface recession. This work is the first part of a code validation study for new capabilities that were added to 3dFIAT. These expanded capabilities include a multi-block moving grid system and an orthotropic thermal conductivity model. This paper focuses on conditions with minimal shape change in which the fluid/solid coupling is not necessary. Two groups of test cases of 3dFIAT analyses of Phenolic Impregnated Carbon Ablator in an arc-jet are presented. In the first group, axisymmetric iso-q shaped models are studied to check the accuracy of three-dimensional multi-block grid system. In the second group, similar models with various through-the-thickness conductivity directions are examined. In this group, the material thermal response is three-dimensional, because of the carbon fiber orientation. Predictions from 3dFIAT are presented and compared with arcjet test data. The 3dFIAT predictions agree very well with thermocouple data for both groups of test cases.

Chen, Yih-Kanq↗

NASA NTRS2010

Multidimensional Testing of Thermal Protection Materials in the Arcjet Test Facility

Many thermal protection system materials used for spacecraft heatshields have anisotropic thermal properties, causing them to display significantly different thermal characteristics in different directions, when subjected to a heating environment during flight or arcjet tests. The anisotropic effects are enhanced in the presence of sidewall heating. This paper investigates the effects of anisotropic thermal properties of thermal protection materials coupled with sidewall heating in the arcjet environment. Phenolic Impregnated Carbon Ablator (PICA) and LI-2200 materials (the insulation material of Shuttle tiles) were used for this study. First, conduction-based thermal response simulations were carried out, using the Marc.Mentat finite element solver, to study the effects of sidewall heating on PICA arcjet coupons. The simulation showed that sidewall heating plays a significant role in thermal response of these models. Arcjet tests at the Aerodynamic Heating Facility (AHF) at NASA Ames Research Center were performed later on instrumented coupons to obtain temperature history at sidewall and various radial locations. The details of instrumentation and experimental technique are the prime focus of this paper. The results obtained from testing confirmed that sidewall heating plays a significant role in thermal response of these models. The test results were later used to validate the two-dimensional ablation, thermal response, and sizing program, TITAN. The test data and model predictions were found to be in excellent agreement

Agrawal, Parul↗

NASA NTRS2010

Computational Analysis of Arc-Jet Wedge Tests Including Ablation and Shape Change

Coupled fluid-material response analyses of arc-jet wedge ablation tests conducted in a NASA Ames arc-jet facility are considered. These tests were conducted using blunt wedge models placed in a free jet downstream of the 6-inch diameter conical nozzle in the Ames 60-MW Interaction Heating Facility. The fluid analysis includes computational Navier-Stokes simulations of the nonequilibrium flowfield in the facility nozzle and test box as well as the flowfield over the models. The material response analysis includes simulation of two-dimensional surface ablation and internal heat conduction, thermal decomposition, and pyrolysis gas flow. For ablating test articles undergoing shape change, the material response and fluid analyses are coupled in order to calculate the time dependent surface heating and pressure distributions that result from shape change. The ablating material used in these arc-jet tests was Phenolic Impregnated Carbon Ablator. Effects of the test article shape change on fluid and material response simulations are demonstrated, and computational predictions of surface recession, shape change, and in-depth temperatures are compared with the experimental measurements.

Goekcen, Tahir↗

NASA NTRS2010

Radiation Testing of PICA at the Solar Power Tower

Sandia National Laboratory's Solar Power Tower was used to irradiate specimens of Phenolic Impregnated Carbon Ablator (PICA), in order to evaluate whether this thermal protection system material responded differently to potential shock layer radiative heating than to convective heating. Tests were run at 50, 100 and 150 Watts per square centimeter levels of concentrated solar radiation. Experimental results are presented both from spectral measurements on 1- 10 mm thick specimens of PICA, as well as from in-depth temperature measurements on instrumented thicker test specimens. Both spectral measurements and measured in-depth temperature profiles showed that, although it is a porous, low-density material, PICA does not exhibit problematic transparency to the tested high levels of NIR radiation, for all pragmatic cm-to-inch scale thicknesses. PICA acted as a surface absorber to efficiently absorb the incident visible and near infrared incident radiation in the top 2 millimeter layer in the Solar Power Tower tests up to 150 Watts per square centimeter.

White, Susan M.↗

NASA NTRS2009

NASA Materials Research for Extreme Conditions

This Technical Memorandum briefly covers various innovations in materials science and development throughout the course of the American Space program. It details each innovation s discovery and development, explains its significance, and describes the applications of this material either in the time period discovered or today. Topics of research include silazane polymers, solvent-resistant elastomeric polymers (polyurethanes and polyisocyanurates), siloxanes, the Space Shuttle thermal protection system, phenolic-impregnated carbon ablator, and carbon nanotubes. Significance of these developments includes the Space Shuttle, Apollo programs, and the Constellation program.

Sharpe, R. J.↗

NASA NTRS2010

Radiation Testing of PICA at the Solar Power Tower

White, Susan↗

NASA NTRS2011

Two-Dimensional Finite Element Ablative Thermal Response Analysis of an Arcjet Stagnation Test

The finite element ablation and thermal response (FEAtR, hence forth called FEAR) design and analysis program simulates the one, two, or three-dimensional ablation, internal heat conduction, thermal decomposition, and pyrolysis gas flow of thermal protection system materials. As part of a code validation study, two-dimensional axisymmetric results from FEAR are compared to thermal response data obtained from an arc-jet stagnation test in this paper. The results from FEAR are also compared to the two-dimensional axisymmetric computations from the two-dimensional implicit thermal response and ablation program under the same arcjet conditions. The ablating material being used in this arcjet test is phenolic impregnated carbon ablator with an LI-2200 insulator as backup material. The test is performed at the NASA, Ames Research Center Interaction Heating Facility. Spatially distributed computational fluid dynamics solutions for the flow field around the test article are used for the surface boundary conditions.

Dec, John A.↗

NASA NTRS2012

Quantitative Spectral Radiance Measurements in the HYMETS Arc Jet

Calibrated spectral radiance measurements of gaseous emission spectra have been obtained from the HYMETS (Hypersonic Materials Environmental Test System) 400 kW arc-heated wind tunnel at NASA Langley Research Center. A fiber-optic coupled spectrometer collected natural luminosity from the flow. Spectral radiance measurements are reported between 340 and 1000 nm. Both Silicon Carbide (SiC) and Phenolic Impregnated Carbon Ablator (PICA) samples were placed in the flow. Test gases studied included a mostly-N2 atmosphere (95% nitrogen, 5% argon), a simulated Earth Air atmosphere (75% nitrogen, 20% oxygen, 5% argon) and a simulated Martian atmosphere (71% carbon dioxide, 24% nitrogen, 5% argon). The bulk enthalpy of the flow was varied as was the location of the measurement. For the intermediate flow enthalpy tested (20 MJ/kg), emission from the Mars simulant gas was about 10 times higher than the Air flow and 15 times higher than the mostly-N2 atmosphere. Shock standoff distances were estimated from the spectral radiance measurements. Within-run, run-to-run and day-to-day repeatability of the emission were studied, with significant variations (15-100%) noted.

Danehy, Paul M.↗

NASA NTRS2012

Testing of Candidate Rigid Heatshield Materials at LHMEL for the Entry, Descent, and Landing Technology Development Project

The material testing results described in this paper were part of a material development program of vendor-supplied, proposed heat shield materials. The goal of this program was to develop low density, rigid material systems with an appreciable weight savings over phenolic-impregnated carbon ablator (PICA) while improving material response performance. New technologies, such as PICA-like materials in honeycomb or materials with variable density through-the-thickness were tested. The material testing took place at the Wright-Patterson Air Force Base Laser Hardened Materials Laboratory (LHMEL) using a 10.6 micron CO2 laser operating with the test articles immersed in a nitrogen-gas environment at 1 atmosphere pressure. Test measurements included thermocouple readings of in-depth temperatures, pyrometer readings of surface temperatures, weight scale readings of mass loss, and sectioned-sample readings of char depth. Two laser exposures were applied. The first exposure was at an irradiance of 450 W/cm2 for 50 or 60 seconds to simulate an aerocapture maneuver. The second laser exposure was at an irradiance of 115 W/cm2 for 100 seconds to simulate a planetary entry. Results from Rounds 1 and 2 of these screening tests are summarized.

Sepka, Steven↗