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NASA NTRS2009

Turbulent Wing-Leading-Edge Correlation Assessment for the Shuttle Orbiter

This study was conducted in support of the Orbiter damage assessment activity that takes place for each Shuttle mission since STS-107 (STS - Space Transportation System). As part of the damage assessment activity, the state of boundary layer (laminar or turbulent) during reentry needs to be estimated in order to define the aerothermal environment on the Orbiter. Premature turbulence on the wing leading edge (WLE) is possible if a surface irregularity promotes early transition and the resulting turbulent wedge flow contaminates the WLE flow. The objective of this analysis is to develop a criterion to determine if and when the flow along the WLE experiences turbulent heating given an incoming turbulent boundary layer that contaminates the attachment line. The data to be analyzed were all obtained as part of the MH-13 Space Shuttle Orbiter Aerothermodynamic Test conducted on a 1.8%-scale Orbiter model at Calspan/University of Buffalo Research Center in the Large Energy National Shock Tunnels facility. A rational framework was used to develop a means to assess the state of the WLE flow on the Orbiter during reentry given a contaminated attachment-line flow. Evidence of turbulent flow on the WLE has been recently documented for a few STS missions during the Orbiter s flight history, albeit late in the reentry trajectory. The criterion developed herein will be compared to these flight results.

King, Rudolph A.↗

NASA NTRS1972

Hypersonic aerothermal characteristics of a manned low finenes ratio shuttle booster

An investigation of a winged booster model having canards and an ascent configuration comprised of the booster mounted in tandem with an orbiter model has been conducted at Mach 10.2 in the continuous flow hypersonic tunnel. Longitudinal and lateral directional force characteristics were obtained over angle of attack ranges of -12 deg to 60 deg for the booster and -11 deg to 11 deg for the ascent configuration. Interference heating effects on the booster using the phase-change coating technique were determined at 0 deg angle of attack. Some oil flow photographs of the isolated booster and orbiter and ascent configuration are also presented.

Bernot, P. T.↗

NASA NTRS1991

External tank aerothermal design criteria verification

If a Space Shuttle Main Engine (SSME) fails during the initial 160 seconds of the Shuttle flight, a return-to-launch-site maneuver will be implemented. The period of concern for this task is the pitch-around maneuver when the vehicle is flying backward. The intent of this report is to identify and define the flowfield at the most critical locations from an environment perspective. The solution procedure used to predict the plume heating rates involves both computational analysis and engineering modeling.

Praharaj, Sarat C.↗

NASA NTRS1979

A study of the aerothermal entry environment

Turbulent flow-field solutions are presented for the forebody of a probe entering a nominal Jupiter atmosphere. A two-layer eddy viscosity model is used throughout the study. The solutions that include coupled ablation injection are significant in that they are the first flow-field solutions for a 45-deg spherically blunted cone, the forebody configuration for the Galileo probe. The sphere-cone solutions that include coupled ablation injection show that the radiative heating on much of the conical portion of the probe often exceeds the radiative heating predicted for the corresponding no-injection solution. Turbulence produces a marked decrease in the effectiveness of the ablation products to absorb radiation because of the way in which turbulence alters the structure and composition of the flow. Selected laminar and turbulent solutions are presented for a hyperboloid that demonstrate the effect of turbulence and probe configuration on surface heating and ablative mass loss. Furthermore, the sensitivity of the heating to variations in the turbulence model is presented for the sphere-cone configuration.

Moss, J. N.↗

NASA NTRS1992

An Engineering Method for Interactive Inviscid-Boundary Layers in Three-Dimensional Hypersonic Flows

An engineering method has been developed that couples an approximate three dimensional inviscid technique with the axisymmetric analog and a set of approximate convective heating equations. The displacement effect on the boundary layer on the outer inviscid flow is calculated and included as a boundary condition in the inviscid technique. This accounts for the viscous interaction present at lower Reynolds numbers. The method is applied to blunted axisymmetric and three dimensional elliptic cones at angle of attack for the laminar hypersonic flow of a perfect gas. The method is applied to turbulent and equilibrium-air conditions. The present technique predicts surface heating rates, pressures, and shock shapes that compare favorably with experimental (ground-test and flight) data and numerical solutions of the Navier-Stokes and viscous shock-layer equations. In addition, the inclusion of viscous interaction significantly improves results obtained at lower Reynolds numbers. The new technique represents a major improvement over current engineering aerothermal methods with only a modest increase in computational effort.

Riley, Christopher J.↗

NASA NTRS2002

Arc Jet Testing of the TIRS Cover Thermal Protection System for Mars Exploration Rover

This paper summarizes the arc jet test results of the Mars Exploration Rover (MER) Silicone Impregnated Reusable Ceramic Ablator (SIRCA) Transverse Impulse Rocket System (TIRS) Cover test series in the Panel Test Facility (PTF) at NASA Ames Research Center (ARC). NASA ARC performed aerothermal environment analyses, TPS sizing and thermal response analyses, and arc jet testing to evaluate the MER SIRCA TIRS Cover design and interface to the aeroshell structure. The primary objective of this arc jet test series was to evaluate specific design details of the SIRCA TIRS Cover interface to the MER aeroshell under simulated atmospheric entry heating conditions. Four test articles were tested in an arc jet environment with various sea] configurations. The test condition was designed to match the predicted peak flight heat load at the gap region between the SIRCA and the backshell TPS material, SLA-561S, and resulted in an over-test (with respect to heat flux and heat load) for the apex region of the SIRCA TIRS Cover. The resulting pressure differential was as much as twenty times that predicted for the flight case, depending on the location, and there was no post-test visual evidence of over-heating or damage to the seal, bracket, or backshell structure. The exposed titanium bolts were in good condition at post-test and showed only a small amount of oxidation at the leading edge locations. Repeatable thermocouple data were obtained and SIRCA thermal response analyses were compared to applicable thermocouple data. For the apex region of the SIRCA TIRS Cover, a one-dimensional thermal response prediction proved overly conservative, as there were strong multi-dimensional conduction effects evident from the thermocouple data. The one-dimensional thermal response prediction compared well with the thermocouple data for the leading edge "lip" region at the bolt location. In general, the test results yield confidence in the baseline seal design to prevent hot gas ingestion at the bracket and composite aeroshell structure interface.

Szalai, Christine E.↗

NASA NTRSDate not supplied

Development and Sizing of the Mars 2020 Thermal Protection System

The Mars 2020 entry vehicle successfully delivered the Perseverance rover to the Martian surface on 18 February 2021. The entry vehicle aeroshell was shielded from aerodynamic heating with a thermal protection system (TPS) made of three different ablative materials. This paper provides an overview of the methodology and assumptions employed for the thermal sizing and design of the Mars 2020 aeroshell TPS. The sizing results demonstrate that the as-built thicknesses of the TPS materials were sufficient to withstand the predicted aerothermal environments without exceeding temperature limits of the underlying aeroshell structure. This paper also provides an overview of the ground testing performed in NASA arc jet facilities to verify the performance of flight lot TPS materials. Finally, temperature data returned by thermocouples embedded in the flight vehicle TPS are compared with predictions by the thermal response models used in pre-flight TPS sizing.

Mars2020↗

NASA NTRSDate not supplied

Development and Sizing of the Mars 2020 Thermal Protection System

Mars2020↗

NASA NTRS1983

MINIVER upgrade for the AVID system. Volume 3: EXITS user's and input guide

The successful design of thermal protection systems for vehicles operating in atmosphere and near-space environments requires accurate analyses of heating rate and temperature histories encountered along a trajectory. For preliminary design calculations, however, the requirement for accuracy must be tempered by the need for speed and versatility in computational tools used to determine thermal environments and structural thermal response. The MINIVER program was found to provide the proper balance between versatility, speed and accuracy for an aerothermal prediction tool. The advancement in computer aided design concepts at Langley Research Center (LaRC) in the past few years has made it desirable to incorporate the MINIVER program into the LaRC Advanced Vehicle Integrated Design, AVID, system. In order to effectively incorporate MINIVER into the AVID system, several changes to MINIVER were made. The thermal conduction options in MINIVER were removed and a new Explicit Interactive Thermal Structures (EXITS) code was developed. Many upgrades to the MINIVER code were made and a new Langley version of MINIVER called LANMIN was created.

Pond, J. E.↗

NASA NTRSDate not supplied

Uranus Probe Entry and Descent Mission Concept

Introduction: Uranus was identified as the third highest priority flagship mission in the 2012-2022 Planetary Science Decadal Survey. This latest concept study was requested by the Decadal Survey panel to determine NASA’s planetary science priorities from 2022-2032. This study focused on the probe’s entry and descent aspects and associated trades for viable trajectory options. Uranus Mission and Descent Probe: The proposed Uranus Orbiter and Probe (UOP) Flagship mission will investigate Uranus and its surrounding moons using an orbiting spacecraft with a Uranus descent probe. Unlike previous studies the probe release will occur after orbit insertion allowing sufficient separation of critical events during the orbit insertion burn. The probe will be released at an altitude that allows one hour of in situ atmospheric readings that will be relayed to the orbiter. Afterwards the orbiter will transition to the moon tour phase of the mission. The configuration chosen for the entry aeroshell was a 45° sphere-cone. This shape has been used in the past in the Pioneer Venus Galileo missions. However, the nose radius considered in the present study differed from the values used in either of the previous configurations, primarily to reduce the heat flux at the stagnation point. A two-step approach was used in the development of flight trajectories for the chosen configuration. In the first step, the trajectory code POST2 was used to screen the thousands of entry states provided by interplanetary trajectory simulations, which were terminated at an altitude of 2000 km from the reference surface (1 bar) of Uranus. The screening criteria were: (i) optimization of the communication geometry between the entry probe and orbiter to ensure at least 1 hour of science measurements, (ii) peak stagnation point pressures to be less than six bar, (iii) peak heat fluxes to be less than 5 kW/cm2; the latter two constraints being the limits of ground-test capabilities of the arc jets at NASA Ames Research Center. The entry team investigated two trajectories that met the criteria above, a shallow entry (high heat load ~44 kJ/cm2) and a steeper entry (high heat rate ~1950 W/cm2). In the second step, the two bounding candidate entry states from the POST2 screening process were used in developing flight trajectories using TRAJ coupled with FIAT (a materials thermal response and sizing code) and a margins policy to determine a margined uniform thickness (hence mass) of the forward heatshield material based on the aerothermal environments at the stagnation point. Since the combination of TRAJ and FIAT size the TPS based on stagnation point environments only, flow field computations using DPLR were necessary to determine turbulent aerothermal environments on the conical flank, and the augmentation of these environments due to surface roughness. The environments at select locations on the forward heatshield were then used to size the thermal protection material, with the largest thickness value then used to estimate the mass. The newly developed woven thermal protection material –HEEET (Heatshield for Extreme Entry Environments Technology) –was considered for the forward heatshield and PICA (Phenolic-Impregnated Carbon Ablator) was considered for the backshell. These NASA-developed materials are at TRL 6 and TRL 9, respectively. Furthermore, two options were considered for the HEEET material: (i) a dual-layer option with a denser recession layer on top and an insulative layer underneath it, and (ii) a single layer option consisting of the insulative layer alone. Results: It is clear that probe entry states are feasible and the selected TPS options are able to perform in the predicted aerothermal environments thus enabling the mission to meet of the descent probe portion of this flagship mission

Entry Descent and Landing↗

NASA NTRS1983

MINIVER upgrade for the AVID system. Volume 1: LANMIN user's manual

The successful design of thermal protection systems for vehicles operating in atmosphere and near space environments requires accurate analyses of heating rate and temperature histories encountered along a trajectory. For preliminary design calculations, however, the requirement for accuracy must be tempered by the need for speed and versatility in computational tools used to determine thermal environments and structural thermal response. The MINIVER program has been found to provide the proper balance between versatility, speed and accuracy for an aerothermal prediction tool. The advancement in computer aided design concepts at Langley Research Center (LaRC) in the past few years has made it desirable to incorporate the MINIVER program into the LaRC Advanced Vehicle Integrated Design, AVID, system. In order to effectively incorporate MINIVER into the AVID system, several changes to MINIVER were made. The thermal conduction options in MINIVER were removed and a new Explicit Interactive Thermal Structures (EXITS) code was developed. Many upgrades to the MINIVER code were made and a new Langley version of MINIVER called LANMIN was created. The theoretical methods and subroutine functions used in LANMIN are described.

Engel, C. D.↗

NASA NTRS1989

Experience with advanced instrumentation in a hot section cascade

The Lewis Research Center gas turbine Hot Section Test Facility was developed to provide a real engine environment with known boundary conditions for the aerothermal performance evaluation and verification of computer design codes. This verification process requires experimental measurements in a hostile environment. The research instruments used in this facility are presented, and their characteristics and how they perform in this environment are discussed. The research instrumentation consisted of conventional pressure and temperature sensors, as well as thin-film thermocouples and heat flux gages. The hot gas temperature was measured by an aspirated temperature probe and by a dual-element, fast-response temperature probe. The data acquisition mode was both steady state and time dependent. These experiments were conducted over a wide range of gas Reynolds numbers, exit gas Mach numbers, and heat flux levels. This facility was capable of testing at temperatures up to 1600 K, and at pressures up to 18 atm. These corresponded to an airfoil exit Reynolds number range of 0.5 x 10(6) to 2.5 x 10(6) based on the airfoil chord of 5.55 cm. The results characterize the performance capability and the durability of the instrumentation. The challenge of making measurements in hostile environments is also discussed. The instruments exhibited more than adequate durability to achieve the measurement profile. About 70 percent of the thin-film thermocouples and the dual-element temperature probe survived several hundred thermal cycles and more than 35 hr at gas temperatures up to 1600 K. Within the experimental uncertainty, the steady-state and transient heat flux measurements were comparable and consistent over the range of Reynolds numbers tested.

Yeh, Frederick C.↗

NASA NTRS1995

Shuttle orbiter experiments: Use of an operational vehicle for advancement and validation of space systems design technologies

The NASA Orbiter Experiments (OEX) Program provided a mechanism for utilization of an operational space shuttle orbiter as a flight research vehicle, as an adjunct to its normal space transportation mission. OEX Program experiments were unique among orbiter payloads, as the research instrumentation for these experiments were carried as integral parts of the vehicle's structure, rather than being placed in the orbiter's payload bay as mission-unique cargo. On each of its first 17 flights, the Orbiter Columbia carried some type of research instrumentation. Various instrumentation systems were used to measure, in flight, the requisite parameters for determination of the orbiter aerodynamic characteristics over the entire entry flight regime and/or the aerodynamic-heating rates imposed upon the vehicle during the hypersonic portion of atmospheric entry. The data derived from this instrumentation represent benchmark hypersonic flight data heretofore unavailable for a lifting entry vehicle. The data are being used in a continual process of validation of state-of-the-art methods, both experimental and computational, for simulating/predicting the aerodynamic and aerothermal characteristics of advanced space transportation vehicles. This paper describes the OEX Program complement of research experiments, presents typical flight data obtained by these experiments, and demonstrates the utilization of these data for advancement and validation of vehicle aerothermodynamic-design tools. By example, the concept of instrumenting operational vehicles and/or spacecraft in order to perform advanced technology development and validation is demonstrated to be an effective and economical method for maturing space-systems design technologies.

Holloway, Paul F.↗

NASA NTRSDate not supplied

Aerothermal Analysis of the Dragonfly Titan Entry

Dragonfly is an upcoming NASA New Frontiers mission that will send a rotorcraft lander to Saturn’s moon Titan [1]. This will be the first spacecraft to land on Titan since the Huygens probe’s descent in 2005 and only the second spacecraft overall to enter Titan’s atmosphere. With its dense N 2 atmosphere containing trace amounts of CH 4 , Titan provides a unique entry environment with an unusually long entry sequence and significant radiant heating at relatively low velocities. To address these challenges, the Dragonfly entry capsule design is informed by state-of-the-art aerothermodynamic analysis tools and methodologies that will be laid out in this poster.

EDL↗

NASA NTRS2012

Performance of Conformable Phenolic Impregnated Carbon Ablator in Aerothermal Environments

Conformable Phenolic Impregnated Carbon Ablator, a cousin of Phenolic Impregnated Carbon Ablator (PICA), was developed at NASA Ames Research Center as a lightweight thermal protection system under the Fundamental Aeronautics Program. PICA is made using a brittle carbon substrate, which has a very low strain to failure. Conformable PICA is made using a flexible carbon substrate, a felt in this case. The flexible felt significantly increases the strain to failure of the ablator. PICA is limited by its thermal mechanical properties. Future NASA missions will require heatshields that are more fracture resistant than PICA and, as a result, NASA Ames is working to improve PICA's performance by developing conformable PICA to meet these needs. Research efforts include tailoring the chemistry of conformable PICA with varying amounts of additives to enhance mechanical properties and testing them in aerothermal environments. This poster shows the performance of conformable PICA variants in arc jets tests. Some mechanical and thermal properties will also be presented.

ablative materials↗

NASA NTRS2016

System Level Aerothermal Testing for the Adaptive Deployable Entry and Placement Technology (ADEPT)

The Adaptive Deployable Entry and Placement Technology (ADEPT), a mechanically deployable entry vehicle technology, has been under development at NASA since 2011. As part of the technical maturation of ADEPT, designs capable of delivering small payloads (10 kg) are being considered to rapidly mature sub 1 m deployed diameter designs. The unique capability of ADEPT for small payloads comes from its ability to stow within a slender volume and deploy to achieve a mass efficient drag surface with a high heat rate capability. The low ballistic coefficient results in entry heating and mechanical loads that can be met by a revolutionary three-dimensionally woven carbon fabric supported by a deployable skeleton structure. This carbon fabric has test proven capability as both primary structure and payload thermal protection system. In order to rapidly advance ADEPTs technical maturation, the project is developing test methods that enable thermostructural design requirement verification of ADEPT designs at the system level using ground test facilities. Results from these tests are also relevant to larger class missions and help us define areas of focused component level testing in order to mature material and thermal response design codes. The ability to ground test sub 1 m diameter ADEPT configurations at or near full-scale provides significant value to the rapid maturation of this class of deployable entry vehicles. This paper will summarize arc jet test results, highlight design challenges, provide a summary of lessons learned and discuss future test approaches based upon this methodology.

Hypersonic↗

NASA NTRS2011

Thermal Protection System Aerothermal Screening Tests in HYMETS Facility

The Entry, Descent, and Landing (EDL) Technology Development Project has been tasked to develop Thermal Protection System (TPS) materials for insertion into future Mars Entry Systems. A screening arc jet test of seven rigid ablative TPS material candidates was performed in the Hypersonic Materials Environmental Test System (HYMETS) facility at NASA Langley Research Center, in both an air and carbon dioxide test environment. Recession, mass loss, surface temperature, and backface thermal response were measured for each test specimen. All material candidates survived the Mars aerocapture relevant heating condition, and some materials showed a clear increase in recession rate in the carbon dioxide test environment. These test results supported subsequent down-selection of the most promising material candidates for further development.

thermal protection systems (TPS)↗

NASA NTRS1976

Performance of a mullite reusable surface insulation system in a hypersonic stream

The thermal and structural performance of a large panel of mullite reusable surface insulation (RSI) tiles was determined by a series of aerothermal tests in the Langley 8-foot high-temperature structures tunnel. The test panel was designed to represent a portion of the surface structure on a space shuttle orbiter fuselage along a 1,150 K isotherm with the mullite tile system bonded directly to the primary structure. Aerothermal tests were conducted at a free-stream Mach number of 6.7, a total temperature of 1,880 K, a unit Reynolds number of 4.6 million per meter, and dynamic pressure of 62 kPa. The thermal response of the mullite tile was as predicted, and the bond-line temperature did not exceed the design level of 570 K during a typical entry-heat cycle. Geometric irregularities of the tile gaps affected the tile edge temperatures when exposed to hypersonic flow. The tile coating demonstrated good toughness to particle impacts, but the coating cracked and flaked with thermal cycles. The gap filler of woven silica fibers appeared to hinder flow penetration into the gaps and withstood the flow shear of the present tests.

Hunt, L. R.↗