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At least 325 records · Page 18

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NASA NTRS2019

Heatshield for Extreme Entry Environment Technology (HEEET) Thermal Protection System (TPS)

Over the last 5 years, the Heatshield for Extreme Entry Environment Technology (HEEET) project has been working to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations with extreme entry environments such as Venus, Saturn, Uranus, Neptune and high speed sample return missions to Earth. A key aspect of the project has been the building and testing of a 1-meter base diameter Engineering Test Unit (ETU) representative of what could be used for a Saturn probe. This paper provides a high level overview of the HEEET project including manufacturing and testing of the ETU which has been subjected to mission relevant thermal and mechanical loads, to verify structural models, establish system capability and verify manufacturing workmanship.

TPS↗

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 NTRSDate not supplied

Multiscale and Multifidelity Modeling of a 3D Woven Composite Thermal Protection System

Complex three-dimensional (3D) woven composites have been considered by multiple NASA projects in recent years as a means of offering improved mechanical and thermal performance over traditional laminated composite systems. Parallel efforts have focused on developing simulation capabilities for these systems, which have traditionally and heavily relied on experimental testing to evaluate composite performance. One system is the Heatshield for Extreme Entry Environment Technology (HEEET), which is being considered for the thermal protection system on reentry spacecraft. Optical microscopy was used to characterize the blended carbon and phenolic fiber tows. A section of HEEET insulation layer was imaged with high-resolution micro-computed tomography (microCT) and segmented to separate individual tows, porous matrix, and voids. These data were used to develop multiscale thermomechanical computational models within the NASA Multiscale Analysis Tool (NASMAT). Two NASMAT modeling approaches were considered to capture the details of the 3D woven architecture: a coarse model appropriate for inclusion in multiscale structural analyses and a high-fidelity model created by downsampling the microCT data. Both elastic and thermal properties were computed and compared. The feasibility and challenges associated with modeling complex, hybrid 3D woven composites were also addressed.

NASMAT↗

NASA NTRSDate not supplied

Advanced TUFROC Thermal Protection System Evolution Under Re-entry like Conditions

Toughened Unipiece Fibrous Reinforced Oxidation-resistant Composite (TUFROC) and its successor, Advanced TUFROC, are state-of-the-art thermal protection systems (TPS) for high temperature reusable applications. Originally designed for use on the wing-leading edge of X-37B, TUFROC is an insulative tiled system consisting of a low-conductivity ceramic base, a carbonaceous cap, and multiple coatings for thermal performance. The improved Advanced TUFROC has demonstrated reusability up to 2900 °F and single use capabilities exceeding 3200 °F. This effort explores the evolution of Advanced TUFROC when exposed to re-entry like conditions via arc jet testing. Chemical reactions and constituent migration resulting from the aerothermal heating are known to occur and are studied in detail. Further, the interaction between the multiple constituents and layers will be discussed as this is believed to have a significant impact on the overall performance. Characterization includes structural analysis via optical microscopy, scanning electron microscopy and energy-dispersive x-ray spectroscopy.

Thermal protection system↗

NASA NTRS1980

Structural tests on a tile/strain isolation pad thermal protection system

The aluminum skin of the space shuttle is covered by a thermal protection system (TPS) consisting of a low density ceramic tile bonded to a matted-felt material called strain insulation pad (SIP). The structural characteristics of the TPS were studied experimentally under selected extreme load conditions. Three basic types of loads were imposed: tension, eccentrically applied tension, and combined in-plane force and transverse pressure. For some tests, transverse pressure was applied rapidly to simulate a transient shock wave passing over the tile. The failure mode for all specimens involved separation of the tile from the SIP at the silicone rubber bond interface. An eccentrically applied tension load caused the tile to separate from the SIP at loads lower than experienced at failure for pure tension loading. Moderate in-plane as well as shock loading did not cause a measurable reduction in the TPS ultimate failure strength. A strong coupling, however, was exhibited between in-plane and transverse loads and displacements.

Williams, J. G.↗

NASA NTRS2002

Improvements in Thermal Protection Sizing Capabilities for TCAT: Conceptual Design for Advanced Space Transportation Systems

The Thermal Calculation Analysis Tool (TCAT), originally developed for the Space Systems Design Lab at the Georgia Institute of Technology, is a conceptual design tool capable of integrating aeroheating analysis into conceptual reusable launch vehicle design. It provides Thermal Protection System (TPS) unit thicknesses and acreage percentages based on the geometry of the vehicle and a reference trajectory to be used in calculation of the total cost and weight of the vehicle design. TCAT has proven to be reasonably accurate at calculating the TPS unit weights for in-flight trajectories; however, it does not have the capability of sizing TPS materials above cryogenic fuel tanks for ground hold operations. During ground hold operations, the vehicle is held for a brief period (generally about two hours) during which heat transfer from the TPS materials to the cryogenic fuel occurs. If too much heat is extracted from the TPS material, the surface temperature may fall below the freezing point of water, thereby freezing any condensation that may be present at the surface of the TPS. Condensation or ice on the surface of the vehicle is potentially hazardous to the mission and can also damage the TPS. It is questionable whether or not the TPS thicknesses provided by the aeroheating analysis would be sufficiently thick to insulate the surface of the TPS from the heat transfer to the fuel. Therefore, a design tool has been developed that is capable of sizing TPS materials at these cryogenic fuel tank locations to augment TCAT's TPS sizing capabilities.

Olds, John R.↗

NASA NTRS2006

In-Space Repair of Reinforced Carbon-Carbon Thermal Protection System Structures

Advanced repair and refurbishment technologies are critically needed for the thermal protection system of current space transportation system as well as for future Crew Exploration Vehicles (CEV). The damage to these components could be caused by impact during ground handling or due to falling of ice or other objects during launch. In addition, in-orbit damage includes micrometeoroid and orbital debris impact as well as different factors (weather, launch acoustics, shearing, etc.) during launch and re-entry. The GRC developed GRABER (Glenn Refractory Adhesive for Bonding and Exterior Repair) material has shown multiuse capability for repair of small cracks and damage in reinforced carbon-carbon (RCC) material. The concept consists of preparing an adhesive paste of desired ceramic with appropriate additives and then applying the paste to the damaged/cracked area of the RCC composites with adhesive delivery system. The adhesive paste cures at 100-120 C and transforms into a high temperature ceramic during simulated entry conditions. A number of plasma torch and ArcJet tests were carried out to evaluate the crack repair capability of GRABER materials for Reinforced Carbon-Carbon (RCC) composites. For the large area repair applications, integrated system for tile and leading edge repair (InSTALER) have been developed. In this presentation, critical in-space repair needs and technical challenges as well as various issues and complexities will be discussed along with the plasma performance and post test characterization of repaired RCC materials.

Singh, Mrityunjay↗

NASA NTRS2011

Thermal protection system ablation sensor

An isotherm sensor tracks space vehicle temperatures by a thermal protection system (TPS) material during vehicle re-entry as a function of time, and surface recession through calibration, calculation, analysis and exposed surface modeling. Sensor design includes: two resistive conductors, wound around a tube, with a first end of each conductor connected to a constant current source, and second ends electrically insulated from each other by a selected material that becomes an electrically conductive char at higher temperatures to thereby complete an electrical circuit. The sensor conductors become shorter as ablation proceeds and reduced resistance in the completed electrical circuit (proportional to conductor length) is continually monitored, using measured end-to-end voltage change or current in the circuit. Thermocouple and/or piezoelectric measurements provide consistency checks on local temperatures.

Gorbunov, Sergey↗

NASA NTRS1978

Study of heat sink thermal protection systems for hypersonic research aircraft

The feasibility of using a single metallic heat sink thermal protection system (TPS) over a projected flight test program for a hypersonic research vehicle was studied using transient thermal analyses and mission performance calculations. Four materials, aluminum, titanium, Lockalloy, and beryllium, as well as several combinations, were evaluated. Influence of trajectory parameters were considered on TPS and mission performance for both the clean vehicle configuration as well as with an experimental scramjet mounted. From this study it was concluded that a metallic heat sink TPS can be effectively employed for a hypersonic research airplane flight envelope which includes dash missions in excess of Mach 8 and 60 seconds of cruise at Mach numbers greater than 6. For best heat sink TPS match over the flight envelope, Lockalloy and titanium appear to be the most promising candidates

Vahl, W. A.↗

NASA NTRS1976

Vibroacoustic testing of Space Shuttle thermal protection system panels

The modes and acoustic responses of two panels representing Space Shuttle thermal protection panels were investigated. The panels consisted of flat aluminum sheet stiffened longitudinally with hat-section stringers and corrugated supporting panels representing Shuttle ring frame bulkheads. In addition, one panel had 24 tiles of LI900 silica thermal insulation material and a strain isolator pad bonded to the face sheet. Both panels were found to have approximately eight modal frequencies in the 60 to 500 Hz range, where Shuttle acoustic loads are expected to be high. The strain response to a progressive acoustic wave representing a Shuttle spectrum was characterized by the occurrence of larger strains in the direction normal to the stringers than in the direction parallel to the stringers; three modes in the 100 to 400 Hz range contributed significantly to the strain response.

Rucker, C. E.↗

NASA NTRS1977

Intumescent-ablators as improved thermal protection materials

Nitroaromatic amine-based intumescent coatings were improved with regard to their thermal protection ability by adding endothermic decomposing fillers with endotherms at or near the exothermic reaction of the intumescent agent, since the effectiveness of the intumescent coatings without fillers is reduced by the exothermic behavior of the coatings during thermal activation. Fillers were dispersed directly in the base coating. Potassium fluoborate, ammonium fluoborate, zinc borate, and ammonium oxalate function as endothermic ablative materials at specific temperature regions, and also enhance the char formation during the intumescent process.

Sawko, P. M.↗

NASA NTRS2019

Heatshield for Extreme Entry Environment Technology (HEEET) Thermal Protection System (TPS)

Starting in 2013 and completing in 2019, the Heatshield for Extreme Entry Environment Technology (HEEET) project has been working to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations with extreme entry environments such as Venus, Saturn, Uranus, Neptune and high-speed sample return missions to Earth. A key aspect of the project has been the building and testing of a 1-meter base diameter Engineering Test Unit (ETU) representative of what could be used for a Saturn probe. This paper provides a high-level overview of the HEEET project including manufacturing and testing of the ETU for structural model verification, establish system capability and verify manufacturing workmanship.

Extreme Entry Environment↗

NASA NTRS1983

The Shuttle Orbiter thermal protection system materials, designs, and flight performance overview

The design requirements for the Orbiter thermal protection system (TPS), the various TPS materials that are used, the different design approaches associated with each of the materials, and the performance experienced during the flight test program are described. The first five flights of the Orbiter Columbia have provided the necessary data to verify the TPS thermal performance, structural integrity, and reusability. The flight performance characteristics of each TPS material are discussed. This discussion is based on postflight inspections and postflight interpretation of the flight instrumentation data. The flights to date indicate that the thermal and structural design requirements for the Orbiter TPS have been met and that the overall performance has been outstanding.

Dotts, R. L.↗

NASA NTRS1971

Fabrication of titanium thermal protection system panels by the NOR-Ti-bond process

A method for fabricating titanium thermal protection system panels is described. The method has the potential for producing wide faying surface bonds to minimize temperature gradients and thermal stresses resulting during service at elevated temperatures. Results of nondestructive tests of the panels are presented. Concepts for improving the panel quality and for improved economy in production are discussed.

Wells, R. R.↗

NASA NTRS2026

Thermal Protection Facility: Taking the Heat

Video highlighting the products and manufacturing capabilities of the Thermal Protection Facility at Kennedy Space Center which is part of the JSC EA/ES division. This record includes an mp4 video with a run time of 9 min. 13 sec.; in color; with sound.

TPSF↗

NASA NTRS2024

Advanced Lightweight TUFROC Thermal Protection System for Space Plane Applications

Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC) represents the state of the art in low-cost, reusable spacecraft Thermal Protection Systems (TPS) with high temperature capability and is flight proven on the USAF X-37B. The two-piece design takes advantage of a low-conductivity porous silica substrate combined with high-temperature-capable carbon cap and surface treatments. NASA has updated the chemical composition of the surface treatments resulting in improved high-heating capability and reusability. The new system, called Advanced TUFROC, experiences a lower surface temperature (by ~80 K) at identical aerothermal heating conditions compared to the original formulation, now called Standard TUFROC. The reduced heating is attributed to the lower catalytic efficiency of the new formulation, which results in reduced exothermic atom recombination rates at the surface. Multiple arc-jet test campaigns demonstrate that Advanced TUFROC has the ability to withstand long and repeated exposures at 1866 K or a shorter duration exposure at 1980 K without recession or damage to TPS. Furthermore, an improved arc-jet article design for assessing 3-dimensional flow over a wing leading edge has been developed and tested. This article allows for assessment of heating at a tile gap under flight-relevant conditions at significantly reduced article fabrication and arc-jet facility configuration costs compared to prior work.

TUFROC↗

NASA NTRS2005

Nanostructured Thermal Protection Systems for Space Exploration Missions

Strong research and development programs in nanotechnology and Thermal Protection Systems (TPS) exist at NASA Ames. Conceptual studies have been undertaken to determine if new, nanostructured materials (composites of existing TPS materials and nanostructured composite fibers) could improve the performance of TPS. To this end, we have studied various candidate heatshields, some composed of existing TPS materials (with known material properties), to provide a baseline for comparison with others that are admixtures of such materials and a nanostructured material. In the latter case, some assumptions were made about the thermal conductivity and strength of the admixture, relative to the baseline TPS material. For the purposes of this study, we have made the conservative assumption that only a small fraction of the remarkable properties of carbon nanotubes (for example) will be realized in the material properties of the admixtures employing them. The heatshields studied included those for Sharp leading edges (appropriate to out-of-orbit entry and aero-maneuvering), probes, an out-of-orbit Apollo Command Module (as a surrogate for NASA's new Crew Exploration Vehicle [CEV]), a Mars Sample Return Vehicle and a large heat shield for Mars aerocapture missions. We report on these conceptual studies, which show that in some cases (not all), significant improvements in the TPS can be achieved through the use of nanostructured materials.

Arnold, J. O.↗