3D Printing Heat Shields: An Overview of the AMTPS Project
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Thermal protection systems↗
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Increasing Flexibility of Polymers in the Application of Complex Space Craft Heat Shield Geometries
Highly crosslinked polymers, commonly utilized in spacecraft component fabrication, especially for heatshields, have historically encountered challenges due to their inherent brittleness. To overcome this issue, researchers have explored the incorporation of additives into the polymer backbone to enhance flexibility and durability. This study aims to improve the flexibility and durability of highly crosslinked polymers by introducing long-chain aliphatic silicon-based additives with varying molecular weights into the polymer backbone. By increasing the flexibility of these brittle polymers, they can be effectively employed in constructing intricate curvatures for heatshields, eliminating the need for gap fillers. In this study, we investigated six different additives, comparing them to a highly crosslinked high-temperature polymer used as a baseline. Various characterization techniques, including thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), dilatometry, dynamic mechanical analysis (DMA), nuclear magnetic resonance (NMR), and Fourier transform infrared spectroscopy (FTIR), were employed to assess the properties of the materials. The FTIR and NMR results indicated the successful incorporation of the silicon-based additives into the polymer backbone. Furthermore, thermal characterization results demonstrated that certain additives exhibited superior flexibility and lower densities compared to the baseline polymer.
Tane Boghozian↗
Developmental Flight Heat Shield Instrumentation Technologies
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Bohdan O Wesely↗
Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials (3MDCP)
Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.
Woven↗
Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials
Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.
Discrete Element Method↗
AVCOAT Density Characterization for Orion Multi-Purpose Crew Vehicle
The Orion Multi-Purpose Crew Vehicle (MPCV) will transport four crew members to and from lunar-class orbital destinations. The first orbital Exploration Flight Test (EFT-1) is scheduled for December 2014 and will provide valuable data on several systems, including the heat shield. The heat shield material is AvcoatTM, a mid-density ablator. Specifically, the heat shield contains a fiberglass-phenolic honeycomb structure filled with an ablative epoxy novolac resin. Post-flight characterization of the EFT-1 thermal protection system will be conducted in order to study the material response and measure the char front of the material. Avcoat density profiling will be conducted to study three critical material zones: char, pyrolysis, and virgin states as a function of material depth. As part of a ground test campaign, Avcoat coupons are tested at the NASA Ames Research Center Arc Jet Complex. The test campaign is set forth to study material response based on environments, perform Avcoat material density characterization, and compare the char depths from the HEAT sensor and density profiling studies. These investigations will then be compared to flight data in order to improve upon TPS material response models.
AVCOAT↗
EMC3-EIRENE simulation of first wall recycling fluxes in W7-X with relation to H-alpha measurements
In the Wendelstein 7-X stellarator, the main locations of particle sources are expected to be the carbon divertors, baffles and graphite heat shield first wall. In this paper, the heat shield is implemented in EMC3-EIRENE to understand the expected areas and magnitudes of the recycling flux to this component. It is found that in the simulation the heat shield is not a significant source of recycling neutrals. The areas of simulated recycling flux are shown to correlate well with footprints of plasma-wetting seen in post-experimental campaign in-vessel inspection photos. EMC3-EIRENE reconstruction of line-integrated H-alpha measurements at the heat shield indicate that the majority of emission does not come from local recycling neutrals. Rather, the H-alpha signals at the heat shield are dominated by ionization of neutrals which have leaked from the divertor/baffle region into the midplane. The magnitude of the H-alpha line emission from the synthetic reconstruction is consistent with the experiment, indicating that a large overestimation of heat shield recycling would occur if these measurements were assumed to be from local recycling sources. In the future, it may be possible to obtain some information of local recycling from the heat shield since it was found that the majority of the recycling flux occurs on two well-localized areas.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Effect of probe configuration on radiative heating during Jovian entry
The radiative heating to the probe's surface and the effects of the recession of the heat shield caused by this heating are analyzed for five initial probe configurations for a Jovian entry. The initial configurations are spherically capped, conical bodies and hyperboloids. The results show that severe blunting of the nose region occurs for all configurations due to ablation of the heat shield caused by the large radiative heating rates. Recession at the nose region can possibly cause a concavity at the stagnation point. Furthermore, the recession of the heat shield, especially for the spherically capped, conical bodies, will be underpredicted if the change in the probe's shape during the entry is neglected in an analysis.
Sutton, K.↗
Re-evaluation of heat-transfer data obtained in flight tests of heat-sink shielded re-entry vehicles.
Stagnation point velocity and pressure distribution over heat-sink shielded reentry vehicle to test boundary layer heat transfer theories
HEAT SHIELD↗
SOME CONSIDERATIONS OF THE PERFORMANCE OF A MANEUVERABLE, LIFTING-BODY, ENTRY VEHICLE
Heating and heat-shield requirements for maneuverable, lifting body, entry vehicle
LIFTING REENTRY↗
NASA Crew Exploration Vehicle, Thermal Protection System, Lessons Learned
The Orion (CEV) thermal protection system (TPS) advanced development project (ADP) was initiated in late 2006 to reduce developmental risk by significant investment in multiple heat shield architectural solutions that can meet the needs both the Low Earth orbit (LEO) and Lunar return missions. At the same time, the CEV TPS ADP was also charged with developing a preliminary design for the heat shield to meet the PDR requirement and at the time of the PDR, transfer the design to Lockheed- Martin, the prime contractor. We reported on the developmental activities of the first 18 months at the IPPW5 in Bordeaux, France, last summer. In June 08, at the time of the IPPW6, the CEV TPS ADP would have nearly completed the preparation for the Orion PDR and would be close to the original three-year mark. We plan to report on the progress at the Atlanta workshop. In the past year, Orion TPS ADP investment in TPS Technology, especially in PICA ablative Heat-shield design, development, testing and engineering (DDTE) has paid off in enabling MSL mission to switch from SLA 561 V heat shield to PICA heat shield. CEV TPS ADP considered SLA 561 V as a candidate for LEO missions and our testing identified failure modes in SLA and as a result, we dropped SLA for further evaluation. This close synergy between two projects is a highly visible example of how investment in technology areas can and does benefit multiple missions. In addition, CEV TPS ADP has been able to revive the Apollo ablative system namely AVCOAT honeycomb architecture as an alternate to the baseline PICA architecture and we plan to report the progress we have made in AVCOAT. CEV TPS ADP has invested considerable resources in developing analytical models for PICA and AVCOAT, material property measurements that is essential to the design of the heat-shield, in arcjet testing, in understanding the differences between different arc jet facilities, namely NASA Ames, NASA JSC and Air Force's AEDC, and in Non-Destructive Evaluation (NDE), and in integration of and manufacturing heat shield as a system. The capabilities of the two heat shield systems including failure modes via testing and analysis, once established, can serve the Probe Community and future mission designers to inner and outer planetary exploration very well. For example, missions to Venus, Mars and Titan can use either one of the system by selecting the mission design parameters that utilizes the full characteristics of these system to make use of system efficiency that will result in reduced heat shield mass, system robustness that will enhance mission success and cost. We plan to present significant progresses of the past three years and highlight the significant contributions CEV TPS ADP Project has made to advance the state of the art in Thermal Protection System technology that has and will continue to benefit future entry probe missions.
NASA Crew Exploration Vehicle↗
A Fast Code for Jupiter Atmospheric Entry Analysis
A fast code was developed to calculate the forebody heating environment and heat shielding that is required for Jupiter atmospheric entry probes. A carbon phenolic heat shield material was assumed and, since computational efficiency was a major goal, analytic expressions were used, primarily, to calculate the heating, ablation and the required insulation. The code was verified by comparison with flight measurements from the Galileo probe's entry. The calculation required 3.5 sec of CPU time on a work station, or three to four orders of magnitude less than for previous Jovian entry heat shields. The computed surface recessions from ablation were compared with the flight values at six body stations. The average, absolute, predicted difference in the recession was 13.7% too high. The forebody's mass loss was overpredicted by 5.3% and the heat shield mass was calculated to be 15% less than the probe's actual heat shield. However, the calculated heat shield mass did not include contingencies for the various uncertainties that must be considered in the design of probes. Therefore, the agreement with the Galileo probe's values was satisfactory in view of the code's fast running time and the methods' approximations.
Tauber, Michael E.↗
Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program
This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.
Stewart, Michael↗
Thermal design of inflatable spherical shadow shields
Heat transfer from balloon type shadow shield to cryogen storage tank - mathematical discussion
Campbell, J. P.↗
Low NO.sub.x combustor
A combustor includes a dome assembly having radially outer and inner liners joined thereto and defining therebetween a combustion zone. The dome assembly includes at least one annular dome having a pair of axially extending first flanges between which are disposed a plurality of circumferentially spaced apart carburetors for discharging a fuel/air mixture into the combustion zone for generating combustion gases. An annular heat shield includes a pair of axially extending legs integrally joined to a radially extending face in a generally U-shaped configuration, with the face including a plurality of circumferentially spaced apart ports disposed concentrically with perspective ones of the carburetors for allowing the fuel/air mixture to be discharged therefrom through the heat shield. At least one of the heat shield legs includes a plurality of circumferentially spaced apart mounting holes disposed adjacent to a respective one of the dome flanges, and a plurality of mounting pins are fixedly joined to the dome flange and extend radially through respective ones of the mounting holes without interference therewith for allowing unrestrained thermal movement between the heat shield and the dome while supporting the heat shield against axial pressure loads thereon. In a preferred embodiment, the dome assembly includes three domes having respective ones of the heat shield, and respective baffles are spaced from the heat shields for providing impingement cooling thereof.
Halila, Ely E.↗
A Fast Code for Jupiter Atmospheric Entry
A fast code was developed to calculate the forebody heating environment and heat shielding that is required for Jupiter atmospheric entry probes. A carbon phenolic heat shield material was assumed and, since computational efficiency was a major goal, analytic expressions were used, primarily, to calculate the heating, ablation and the required insulation. The code was verified by comparison with flight measurements from the Galileo probe's entry; the calculation required 3.5 sec of CPU time on a work station. The computed surface recessions from ablation were compared with the flight values at six body stations. The average, absolute, predicted difference in the recession was 12.5% too high. The forebody's mass loss was overpredicted by 5.5% and the heat shield mass was calculated to be 15% less than the probe's actual heat shield. However, the calculated heat shield mass did not include contingencies for the various uncertainties that must be considered in the design of probes. Therefore, the agreement with the Galileo probe's values was considered satisfactory, especially in view of the code's fast running time and the methods' approximations.
Tauber, Michael E.↗
Effects of scaled heatshield tile misalignment on Orbiter boundary-layer transition
The article addresses the problem of assessing the sensitivity of the heat transfer rate of a Space Orbiter windward surface and boundary-layer transition data to surface features, or 'roughness elements', characteristic of randomly misaligned heat shield tiles. Selected heat shield tiles were precision-formed on the surface of a 0.0175-scale Orbiter model. Selective electroless plating and selective electrochemical etching techniques were employed. Effects of roughness on the location of boundary-layer transition were markedly influenced by the wall-to-total temperature ratios, according to wind-tunnel test results.
Goodrich, W. D.↗
Thermal design of inflatable spherical shadow shields.
Heat transfer from inflatable spherical balloon shadow shield to spherical cryogen storage tank, noting several design factors and extensions of previous work
Campbell, J. P.↗