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NASA NTRSDate not supplied

Qualification of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90’s. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions, from Sample Return missions such as Stardust, OSIRIS-REx to large Mars Lander missions such as Mars Science Lab (MSL) and Mars 2020. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues. The challenge involved in finding a replacement fiber source is in processing as well as in the final performance of the ablator. Each replacement necessitates the requalification of the PICA. This has happened at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Due to its flight heritage and proven capability, PICA is baselined as the Thermal Protection System (TPS) for Dragonfly and Mars Sample Return Sample Retrieval Lander mission and is being considered for the backshell of the Mars Sample Return Earth Entry System. All three missions are due to be launched between 2026 and 2028. The challenge this time is to ensure the PICA made with domestic material is a suitable replacement to the heritage PICA used in MSL and Mars 2020 so that the design of the heatshield can be matured without much risk. Results are presented from the recent efforts of 22 PICA-D billets that were Lot Acceptance Tested. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Testing of PICA-Domestic (PICA-D) indicates very comparable performance with respect to “heritage” PICA materials and thus PICA-D is expected to be a sustainable and nearly a “drop-in” replacement solution for future NASA missions.

PICA↗

NASA NTRSDate not supplied

Towards the Prediction of Entry Capsule Dynamic Stability Characteristics with Reduced Free Flight Motion in FUN3D

Work is done to verify FUN3D's 6-DOF path and begin active application to flight projects. This work moves towards a computational predictive capability for entry capsule dynamic stability such that data from concurrent ground testing will enable validation efforts of this solver and its continued use on EDL vehicles. Applications of the solver to the Dragonfly mission to Titan and the Mars Sample Return - Earth Entry System are discussed.

Eli Shellabarger↗

NASA NTRSDate not supplied

Contamination monitoring of the OSIRIS-REx ISO5 asteroid sample cleanroom

The OSIRIS-REx mission to asteroid Bennu successfully collected hundreds of grams of asteroid regolith in October 2020 [1]. The spacecraft departed Bennu in May 2021 for Earth return and will release the sample canister to be recovered in Utah in September 2023 [2]. Samples will be transported to the curation facility at NASA Johnson Space Center, where an ISO5 equivalent cleanroom has been designed in 2017 and completed in 2021. Aspects of the design and material selection for the cleanroom and its supporting facilities (air handling system, cleanroom floors and walls, filters, paints, etc.) were optimized to minimize effects of organic and inorganic contaminants and offgassing [3]. Since its completion, the lab has been carefully monitored to understand and establish a baseline with respect to multiple environmental aspects – measurement of particle counts, deploying Si wafer witness plates for organic and inorganic contaminants, deploying aluminum foils for a focus on organics with JSC in-house expertise, gas samples, and regular microbial and fungal measurements on selected surfaces and air samples in the cleanroom. This contribution will report on nearly one year of monitoring and highlight several specific aspects that have led to a better understanding of the new cleanroom environment.

carbonaceous asteroid↗

NASA NTRSDate not supplied

Enabling Planetary In-Situ and Sample Return Missions: NASA Developed 3-D Woven Thermal Protection / Heatshield Technology for Extreme Entry Environment

Heatshield for Extreme Entry Environment Technology (HEEET) and 3-D Mid-Density Carbon-Phenolic (3MDCP) are two variants of 3-D Woven. TPS funded by STMD and SMD. HEEET was matured to TRL 6 in 2019, and SMD offered it as incentivized technology. Mars Sample Return Earth Entry System has baselined a seamless 3MDCP heatshield, and it will reach TRL 6 by 2025. HEEET and 3MDCP have been tested to withstand entry peak heat-flux ~ 4500 W/sq.cm, pressure ~ 6.5 atm, and shear ~ 4000 Pa. Bally Ribbon Mills and T.E.A.M. Inc developed looms and demonstrated their capability to weave HEEET and 3MDCP respectively. F.M.I. has demonstrated capability to form and resin infuse the preforms, and machine the TPS for final assembly. Expertise to integrate the parts reside at NASA, and NASA can transfer the knowhow to interested parties via technology transfer.

Ethiraj Venkatapathy↗

NASA NTRSDate not supplied

Boundary-Layer Flow Simulations Over Ablating Woven Thermal Protection System Material

Spallation is the mechanical removal of small chunks of material gets removed typically due to high shear conditions of the flow field. This reduces the ability of the thermal protection system (TPS) material to protect the spacecraft as well as cause turbulence in the flow causing higher heating rates. In this work, we focus on the material removal through ablation and high shear flow within the boundary layer region of woven TPS material. Woven TPS (WTPS) material is the latest class of material developed by NASA, to be used within the next generation of space flights. They are complex interlocked weaves designed to create a rigid structure that is highly resistant to heat and can be easily designed and tailored for a wide variety of entry environments. Due to material removal resulting from chemical degradation, the structural integrity of TPS material is affected. Spallation occurs when this structurally compromised material is exposed to the high shear flow conditions within the boundary layer. In order to understand the spallation mechanism within WTPS material, we first perform the material removal simulations which occur primarily through oxidation to obtain the microstructure at various stages of degradation. These simulations are performed using the Porous Microstructure Analysis (PuMA) software developed at NASA Ames. The micro-structure geometry used within these simulations were generated artificially to be similar to the 3D weave architecture of MSR-EEV (Mars Sample Return - Earth Entry Vehicle). The various eroded TPS micro-structures are then subjected to the boundary layer flow conditions to obtain critical surface quantities which contribute to the structural failure mechanism such as heat flux, pressure, and shear stress. The direct simulation Monte Carlo (DSMC) methodology is used to perform these simulations in order to accurately capture the strong gradients within the high-temperature boundary layer flow over the intricate geometry of WTPS material. The boundary layer profile is directly taken from the Computational Fluid Dynamics (CFD) simulation and provided as boundary conditions to the DSMC inlet and outlet. Further, the variation of these properties as the microstructure undergoes changes due to oxidation is also investigated. Finally, these quantities are used as input in PuMA to understand the material expansion/compression and strain within the woven TPS geometry and help in developing a comprehensive spallation and structure failure model.

microstructure↗

NASA NTRSDate not supplied

Boundary-Layer Flow Simulations Over Ablating Woven Thermal Protection System Material

microstructure↗

NASA NTRSDate not supplied

Supersonic Free-Flight Dynamics Testing in the Stratosphere

A new technique for obtaining stratospheric free-flight dynamics data for atmospheric entry capsules is described. The Stratospheric Projectile Experiment of Entry Dynamics (SPEED) represents a new approach to characterizing the free-flight dynamics of vehicles in the supersonic and transonic regime of flight. The SPEED test architecture leverages a stratospheric balloon and 3D-printed flight system in a novel two-stage configuration to deliver test articles to supersonic conditions in the atmosphere which achieve dynamic similitude with a full-scale vehicle. Designed to address the limitations of existing test facilities, SPEED captures the complete time evolution of a vehicle’s dynamic state while producing a statistically significant number of observed flight trajectories to address the stochastic nature of the wake-driven dynamic stability phenomenon. SPEED was developed over two years at NASA Ames Research Center. The inaugural flight of the SPEED test platform was conducted in the summer of 2024 where scaled capsules of the Mars Sample Return Earth Entry System and Dragonfly entry vehicle were tested. This paper describes the motivation for a new test architecture, operational constraints and achievable flight test envelopes, the design and development of the SPEED concept, and results from the demonstration flight. Techniques for estimating the dynamic aerodynamic characteristics and atmospheric conditions for each test article individually and as a collective are also discussed.

Entry Vehicle↗

NASA NTRSDate not supplied

Dynamic Stability Test Technique for Blunt Bodies in a Magnetic Suspension and Balance System

Techniques for the measurement of subsonic dynamic stability derivatives of blunt-body re-entry capsules are being developed using a Magnetic Suspension and Balance System at NASA Langley Research Center. The measured aerodynamics of a 45-degree sphere-cone similar to configurations being considered for Mars Sample Return Earth Entry Vehicle are reported. A novel test method has been developed where forced oscillatory translation of a test article is used to excite yaw attitude oscillations. The forced motion is then halted to observe free-to-oscillate behavior of the test article. Parameter identification methods are used to extract drag as well as static and dynamic yawing moment stability characteristics from the measured forces and observed attitude histories. This combination of forced excitation followed by free-to-oscillate dynamics is a repeatable method to produce test article attitude histories that can be used to measure aerodynamic characteristics.

Entry Systems Modeling↗

NASA NTRSDate not supplied

Dynamic Stability Test Technique for Blunt Bodies in a Magnetic Suspension and Balance System

Entry Systems Modeling↗

NASA NTRSDate not supplied

Multiscale Modeling of Woven Ablative Thermal Protection System Materials

The NASA Entry Systems Modeling project maintains a portfolio of computational model and tool development activities focused on reducing performance uncertainties in ablative Thermal Protection System (TPS) materials for NASA missions. The development activities span material scale and strive to allow microstructural characterization of material structure and properties, mesoscale analyses of damage, and macroscale evaluation of heatshield performance and recession in a given aerothermodynamic environment. This talk will detail the application of developed capabilities at all three scales to the woven TPS material that the Agency has selected as the heatshield for the Mars Sample Return Earth Entry System (MSR-EES) mission – 3D Mid-Density Carbon Phenolic (3MDCP). Each of the applications focuses on driving down uncertainties in material performance and thus risk for MSR-EES and other future missions that may leverage woven TPS. At the microscale, machine learning techniques are used to characterize images from destructive microscopy and inform structural variability. At the mesoscale, Lagrangian techniques are used to simulate ballistic impact and interpret damage modes noted in experiments. At the macroscale, coupled flow-material response techniques are validated by Arc Jet testing to enable heatshield design for missions with massive ablation.

Justin B Haskins↗

NASA NTRS1965

High-energy trajectories from Earth to Mars and return

High energy trajectories from Earth to Mars and return for 1970-1980 - three-dimensional conic approximation used for calculations

EARTH↗

NASA NTRS1963

Lunar Flight Study Series: Volume 5. Trajectories in the Earth-Moon Space with Symmetrical Free Return Properties

An extensive investigation has been made of the characteristics of so-called "free return" trajectories. For the purposes of the study., these trajectories are defined as having certain symmetric properties which afford flight to the vicinity of the moon and return to earth without need for propulsion after the initial boost phase. The restricted three-body model for the earth-moon-probe system is used throughout. Two kinds of free return trajectories are shown to -exist and are studied. Of particular interest is the fact that for one kind of free return path, the largest inclination which can be achieved between the flight plane at periselenum and the plane of the moon's orbit about earth is about 10. 8 degrees while for the other kind of path the largest possible inclination is dependent on ·the radius at periselenum. In this case the inclination is limited to about 14 degrees or less for periselenum radius of 1938 km, but may be as great as 90 degrees with periselenum radius of 21150 km. Trajectories are also demonstrated which pass in front of the moon. These exhibit inclination behavior very much like that given by trajectories which go behind the moon. The injection velocity for these trajectories also changes only slightly from the circumlunar trajectories (less than 2 m/s for periselenum radius of 1938 km). However, the position of injection is changed considerably and the flight time may be increased by as much as five times that for circumlunar flight.

RETURN-TO-EARTH PHASE↗

NASA NTRS1991

Earth aerobraking strategies for manned return from Mars

The atmospheric flight environment of manned return from Mars is evaluated by analyzing the earth-return entry corridor. To identify and quantify the effects of various atmospheric exit conditions on the mission, the differences beween the capture to a specific orbit and the direct entry to a target splashdown site are investigated. The differences are quantified in terms of the airbrake lift-drag ratio requirements, the stagnation-point heating, and the significance of off-nominal atmospheric conditions. Results are presented on three different earth-return aerobraking scenarios: (1) the capture into a phasing orbit with a 24-hr period, (2) the capture into a 500-km circular orbit, and (3) the direct entry to splashdown.

Braun, Robert D.↗

NASA NTRSDate not supplied

NASA Capture, Containment, and Return System: Bringing Mars Samples to Earth

The Capture, Containment, and Return System (CCRS) project is NASA’s last step in bringing back Mars samples. CCRS will close a decades-long multi-mission and multi-agency effort to bring Mars surface samples back to Earth for scientific studies. CCRS will launch in 2027 on the European Earth Return Orbiter (ERO) spacecraft, which will provide communications relay for the Mars Sample Return ground missions, Perseverance rover and the Sample Retrieval Lander (SRL) (to be launched in 2028). The main mission for CCRS begins when the first-ever orbital planetary capture operation occurs with CCRS catching and securing the Orbiting Sample (OS)in low Mars orbit. From this point, the system will perform additional "firsts": it will autonomously contain the OS with heat-shrink-fit, sterilize the outside surface, and assemble the Earth entry capsule, named Earth Entry System (EES), in orbit around Mars using a gantry mechanism. At approximately 2.8 Lunar distances from Earth, or 3-days from entry into Earth’s atmosphere, CCRS will open its micrometeoroid shield and release the EES on a ballistic trajectory to Earth. The EES is designed to be a fully passive system that will enter the atmosphere and land without parachute at the Utah Test and Training Range (UTTR).

Mars mission, Sample return, Mission design↗

NASA NTRS2024

Flight Mechanics Modeling and Simulation of the Earth Entry System

Introduction: The Mars Sample Return (MSR) Campaign being planned by NASA and ESA has the ambitious goal to return Mars samples back to Earth. This international collaboration had developed a concept of operations that included a ESA-designed Earth Return Orbiter (ERO) and NASA-designed Capture, Containment, and Return System (CCRS). The Earth Entry System (EES), consisting of a protective aeroshell that houses the samples as well as sample containment vessels, would conduct entry, descent, and landing (EDL) on a direct Earth trajectory. The EES would enter on a spin-stabilized ballistic trajectory with the goal to passively achieve aerodynamic stability throughout all regions of flight. The EDL sequence would end with the EES impacting the soft playa soil of the Utah Test and Training Range (UTTR). As of the submission of this abstract, the MSR campaign is undergoing a re-architecture leading to a pause in EES development. However, the novel approaches developed in flight mechanics modeling and simulation can significantly benefit the greater IPPW community in the development of Earth return vehicles. This paper will present the latest state of EES flight mechanics modeling and simulation. The paper will highlight the simulation architecture developed and key lessons learned from understanding of EDL trajectory sensitivities. Modeling and Simulation: Figure 1 provides a high-level concept of operations for the approach, entry, descent, and landing (AEDL) phase of the CCRS-portion of MSR. The objective of EES flight mechanics is to model and simulate the EES trajectory from ERO separation to ground impact at UTTR. A variety of flight mechanics simulation models were utilized to model both exo-atmopsheric and atmospheric portions of flight. 42, a 6-DOF simulation developed at Goddard Space Flight Center, is utilized for propagating the attitude of EES during exo-atmospheric flight. 42 allows for a variety of spin eject mechanism scenarios to be simulated for analysis. 10 minutes prior to entry, the 42 states are handed off to the EDL sims. The prime EDL sim utilized by EES is the Program to Optimize Simulated Trajectories II (POST2), a 6-DOF sim developed at Langley Research Center, and the independent verification and validation EDL sim utilized is DSENDS, a 6-DOF sim developed at Jet Propulsion Laboratory. Figure 2 provides a visualization of the flight mechanics simulation model flow through various points in the AEDL phase. Due to the existence of a variety of sim models, the EES flight mechanics team developed processes for data hand-off. These processes included the development of a centralized coordinate frame document, utilization of a single, centralized simulation input document for all sims to reference, and hand-off files containing both the technical data to be ingested by other flight mechanics sims as well as annotations of modeling assumptions utilized to generate the data. Figure~\ref{fig:post2simarchitecture} provides an overview of the POST2 sim architecture wherein POST2 ingests numerous subsystem models and input files. The dispersed state file generated by MONTE provides the position/velocity state of the trajectory while the 42 Handoff file provides the attitude. The aerodynamics database, delivered by the EES aeroscience team, is utilized to simulate the aerodynamic forces and moments experienced during EDL. A custom atmosphere model, developed by EES atmosphere team, is utilized to simulate the anticipated atmosphere environment around the region of Earth through which the EES trajectory flys. These inputs and subsystem models can be varied depending on the AEDL flight mechanics scenario being simulated. Monte Carlo simulations are utilized to generate statistical AEDL performance metrics in the form of scorecards and violin plots. Furthermore, outputs from the POST2 simulation are utilized for follow-on analyses including aerothermal and landing performance. \section{Flight Mechanics Lessons Learned} Though the EES flight mechanics team uncovered a variety of lessons learned through the analysis conducted to support CCRS through preliminary design review, this paper will highlight the most important lessons. A key AEDL performance goal is to ensure the landing footprint of EES remains on the UTTR south range. A common modeling strategy used in EDL analysis is One-Variable-At-a-Time (OVAT). OVAT analysis provides insight into the key drivers that affect AEDL performance metrics. Figure 3 shows the landing ellipses for single dispersion sources as compared to the baseline aggregate of all dispersions. The figure shows that atmosphere winds alone dominate the size of the footprint ellipse (note: EES does not use a parachute unlike previous Earth-return missions and is in wind-driven free fall for ~5min). The significance of the wind led the EES flight mechanics team to pursue the development of a Custom Atmosphere Model [4], in lieu of EarthGRAM [1], built on actual radiosonde wind measurements around the UTTR-region. This decision was driven by the realism in the generated footprint ellipses and lessons-learned from Stardust [5]. These findings will be invaluable for future Earth-return missions in providing an early understanding of the key drivers affecting footprint size and modeling considerations for which to account. Another lesson learned is tied to the AEDL performance goal of achieving passive stability throughout all regions of flight. It is well understood that blunt-body aeroshells are less stable as they transition from supersonic to subsonic. Eliminating a backshell does help improvestability; however, other phenomena such as roll-induced instability during terminal descent can still arise. The EES flight mechanics team developed stability metrics as tools to better understand the causes of and better predict the onset of dynamic instability. These tools were built upon analytical models developed by Jaffe [3] and Murphy [2]. The tools were shown to both be very accurate in correlation with actual unstable cases and useful in developing stability margin policies based on the vehicle design and simulation considerations (e.g. sphere-cone angle change, mass change, wind turbulence). These tools allowed for the current EES design to demonstrate the ability to achieve passive stability and can be an invaluable tool for consideration in the design of parachute-less Earth-return vehicles.

Rohan Deshmukh↗

NASA NTRS2016

An Efficient Approach for Mars Sample Return Using Emerging Commercial Capabilities

Mars Sample Return is the highest priority science mission for the next decade as recommended by the 2011 Decadal Survey of Planetary Science. This article presents the results of a feasibility study for a Mars Sample Return mission that efficiently uses emerging commercial capabilities expected to be available in the near future. The motivation of our study was the recognition that emerging commercial capabilities might be used to perform Mars Sample Return with an Earth-direct architecture, and that this may offer a desirable simpler and lower cost approach. The objective of the study was to determine whether these capabilities can be used to optimize the number of mission systems and launches required to return the samples, with the goal of achieving the desired simplicity. All of the major element required for the Mars Sample Return mission are described. Mission system elements were analyzed with either direct techniques or by using parametric mass estimating relationships. The analysis shows the feasibility of a complete and closed Mars Sample Return mission design based on the following scenario: A SpaceX Falcon Heavy launch vehicle places a modified version of a SpaceX Dragon capsule, referred to as "Red Dragon", onto a Trans Mars Injection trajectory. The capsule carries all the hardware needed to return to Earth Orbit samples collected by a prior mission, such as the planned NASA Mars 2020 sample collection rover. The payload includes a fully fueled Mars Ascent Vehicle; a fueled Earth Return Vehicle, support equipment, and a mechanism to transfer samples from the sample cache system onboard the rover to the Earth Return Vehicle. The Red Dragon descends to land on the surface of Mars using Supersonic Retropropulsion. After collected samples are transferred to the Earth Return Vehicle, the single-stage Mars Ascent Vehicle launches the Earth Return Vehicle from the surface of Mars to a Mars phasing orbit. After a brief phasing period, the Earth Return Vehicle performs a Trans Earth Injection burn. Once near Earth, the Earth Return Vehicle performs Earth and lunar swing-bys and is placed into a Lunar Trailing Orbit - an Earth orbit, at lunar distance. A retrieval mission then performs a rendezvous with the Earth Return Vehicle, retrieves the sample container, and breaks the chain of contact with Mars by transferring the sample into a sterile and secure container. With the sample contained, the retrieving spacecraft makes a controlled Earth re-entry preventing any unintended release of Martian materials into the Earth's biosphere. The mission can start in any one of three Earth to Mars launch opportunities, beginning in 2022.

Commercial↗

NASA NTRS2013

A Mars Sample Return Sample Handling System

We present a sample handling system, a subsystem of the proposed Dragon landed Mars Sample Return (MSR) mission [1], that can return to Earth orbit a significant mass of frozen Mars samples potentially consisting of: rock cores, subsurface drilled rock and ice cuttings, pebble sized rocks, and soil scoops. The sample collection, storage, retrieval and packaging assumptions and concepts in this study are applicable for the NASA's MPPG MSR mission architecture options [2]. Our study assumes a predecessor rover mission collects samples for return to Earth to address questions on: past life, climate change, water history, age dating, understanding Mars interior evolution [3], and, human safety and in-situ resource utilization. Hence the rover will have "integrated priorities for rock sampling" [3] that cover collection of subaqueous or hydrothermal sediments, low-temperature fluidaltered rocks, unaltered igneous rocks, regolith and atmosphere samples. Samples could include: drilled rock cores, alluvial and fluvial deposits, subsurface ice and soils, clays, sulfates, salts including perchlorates, aeolian deposits, and concretions. Thus samples will have a broad range of bulk densities, and require for Earth based analysis where practical: in-situ characterization, management of degradation such as perchlorate deliquescence and volatile release, and contamination management. We propose to adopt a sample container with a set of cups each with a sample from a specific location. We considered two sample cups sizes: (1) a small cup sized for samples matching those submitted to in-situ characterization instruments, and, (2) a larger cup for 100 mm rock cores [4] and pebble sized rocks, thus providing diverse samples and optimizing the MSR sample mass payload fraction for a given payload volume. We minimize sample degradation by keeping them frozen in the MSR payload sample canister using Peltier chip cooling. The cups are sealed by interference fitted heat activated memory alloy caps [5] if the heating does not affect the sample, or by crimping caps similar to bottle capping. We prefer cap sealing surfaces be external to the cup rim to prevent sample dust inside the cups interfering with sealing, or, contamination of the sample by Teflon seal elements (if adopted). Finally the sample collection rover, or a Fetch rover, selects cups with best choice samples and loads them into a sample tray, before delivering it to the Earth Return Vehicle (ERV) in the MSR Dragon capsule as described in [1] (Fig 1). This ensures best use of the MSR payload mass allowance. A 3 meter long jointed robot arm is extended from the Dragon capsule's crew hatch, retrieves the sample tray and inserts it into the sample canister payload located on the ERV stage. The robot arm has capacity to obtain grab samples in the event of a rover failure. The sample canister has a robot arm capture casting to enable capture by crewed or robot spacecraft when it returns to Earth orbit

Wilson, David↗

NASA NTRS2005

Sample Collection from Small Airless Bodies: Examination of Temperature Constraints for the TGIP Sample Collector for the Hera Near-Earth Asteroid Sample Return Mission

There have been a number of missions that have explored the solar system with cameras and other instruments but profound questions remain that can only be addressed through the analysis of returned samples. However, due to lack of appropriate technology, high cost, and high risk, sample return has only recently become a feasible part of robotic solar system exploration. One specific objective of the President s new vision is that robotic exploration of the solar system should enhance human exploration as it discovers and understands the the solar system, and searches for life and resources [1]. Missions to small bodies, asteroids and comets, will partially fill the huge technological void between missions to the Moon and missions to Mars. However, such missions must be low cost and inherently simple, so they can be applied routinely to many missions. Sample return from asteroids, comets, Mars, and Jupiter s moons will be an important and natural part of the human exploration of space effort. Here we describe the collector designed for the Hera Near-Earth Asteroid Sample Return Mission. We have built a small prototype for preliminary evaluation, but expect the final collector to gather approx.100 g of sample of dust grains to centimeter sized clasts on each application to the surface of the asteroid.

Franzen, M. A.↗