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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

3D Woven Mid-Density Carbon Phenolic (3MDCP) Thermal Protection System Development

3-Dimensionally Woven, Mid-Density, Carbon Phenolic (3MDCP) Thermal Protection System (TPS) material is derived from the dual layer 3D woven Heatshield for Extreme Entry Environment Technology (HEEET) material. The baseline 3MDCP design is a single piece thermal protection system that avoids the manufacturing and certification challenges associated with a tiled configuration. 3MDCP is targeted for very aggressive entry environments such as high-speed sample return missions to Earth and missions to Saturn, Venus and the ice giants. A 3MDCP heatshield begins as a flat woven preform that is formed to a given heatshield shape and then infused with phenolic resin. NASA Ames, in collaboration with TEAM Inc. (weaving) and Fiber Materials Inc. (both Spirit AeroSystems Companies) have been developing and demonstrating the manufacturing processes to fabricate a 3MDCP heatshield at a diameter of 1.25 meters. The process of forming the flat woven preform into the final heatshield shape, a sphere-cone geometry, involves local movement of the yarns in the weave. This results in a single piece heatshield with continuous fibers, albeit with property variations between different regions on the heatshield. This presentation will provide a high-level status of 3MDCP development. This will include an overview of the manufacturing processes, with an emphasis on the impact of forming on fiber orientation, material properties and performance. The presentation will layout the plan for testing to assess the impact of forming on properties and review preliminary data comparing properties of flat to formed materials.

Thermal Protection System↗
NASA NTRSDate not supplied

Computational Investigation of Oxidative Etch Pitting in FiberForm and Its Impact on Material Properties

Oxidation-driven carbon erosion does not occur uniformly but rather through the development of localized etch pits at active surface sites. These active sites form due to atomic defects on the carbon surface, making them significantly more reactive than the surrounding, non-defective areas. As a result, these sites are the first to react during ablation, leading to their removal. This process creates new defects in neighboring atoms, increasing their reactivity and causing localized carbon removal around these active sites. In this way, the highly reactive defective areas serve as nucleation points for the formation and growth of etch pits, which can have adverse effects on structural integrity of FiberForm. To better understand how these etch pits impact the material properties of carbon fiber microstructures, we have developed a new capability within the direct simulation Monte Carlo (DSMC) framework to capture the etch pit formation process. This capability, integrated into the DSMC code SPARTA (Stochastic Parallel Rarefied-gas Time-accurate Analyzer), models material removal in the presence of active sites, leading to the formation of etch pits. The current work focuses on studying the effects of these etch pits on the material properties of FiberForm, a widely used base material in thermal protection systems (TPS). The microstructure of virgin FiberForm, obtained via X-ray microtomography, is imported into SPARTA to generate the ablated geometries with etch pits. These modified microstructures are then analyzed using the Porous Microstructure Analysis (PuMA) software to compute various material properties, including elasticity, thermal conductivity, and permeability. We investigate the variation of these properties due to the complex surface topology changes caused by etch pit formation. Additionally, we compare the effects of pitting with the conventional model of shrinking fibers, traditionally used to simulate the ablation of carbon structures. Significant differences emerge between the two approaches. Consequently, this physically realistic model of material removal through etch pit formation offers improved accuracy in predicting the degradation of carbon-based TPS during oxidation. It also provides insights into other mechanisms, such as spallation, where chunks of material are removed into the flow due to etch pit growth. Ultimately, this model enhances our understanding of failure modes in these materials during ablation.

PuMA↗
NASA NTRS1993

Space Shuttle Orbiter thermal protection system design and flight experience

The Space Shuttle Orbiter Thermal Protection System materials, design approaches associated with each material, and the operational performance experienced during fifty-five successful flights are described. The flights to date indicate that the thermal and structural design requirements were met and that the overall performance was outstanding.

Curry, Donald M.↗
NASA NTRS1980

Fire Protection Materials

Avco has drawn upon its heat shield experience to develop a number of widely-accepted commercial fire protection materials. Originating from NASA's space shuttle thermal protection system, one such material is Chartek 59 fireproofing, an intumescent epoxy coating specifically designed for outdoor use by industrial facilities dealing with highly flammable products such as oil refineries and chemical plants. The coating is applied usually by spray gun to exterior structural steel conduits, pipes and valves, offshore platforms and liquefied petroleum gas tanks. Fireproofing provides two types of protection: ablation or dissipation of heat by burn-off and "intumescence" or swelling; the coating swells to about five times its original size, forming a protective blanket of char which retards transfer of heat to the metal structure preventing loss of structural strength and possible collapse which would compound the fire fighting problem.

Source record↗
NASA NTRSDate not supplied

Experimental Investigations into the Material Response of Heatshields, High-Temperature Coatings, and Meteors.

Phenolic Impregnated Carbon Ablator (PICA) gained heritage during the Stardust mission and is the baseline thermal protection system (TPS) material for missions to Mars. However, PICA is friable, so a thin layer of siloxane resin (NuSil) is applied to the surface of the heatshield to suppress the spread of particulate matter during cleanroom activities. Until recently, the thermochemical response of NuSil had not been accounted for in material response models. Therefore, a test campaign was executed at the Hypersonic Materials Environmental Test System (HyMETS) facility to investigate the material response of NuSil and provide crucial insight for model development. Finally, salient results from an experiment supported by the Asteroid Threat Assessment Project (ATAP) will be discussed, which probed the material response of the Tamdakht meteorite and notable analogs. Bio: Dr. Bessire is a senior research scientist in the thermal protection system materials branch at the NASA Ames Research Center. His research focuses on developing analytical techniques designed to inform and validate the development of material response models.

Brody K. Bessire↗
DOE OSTI2023

Enhanced flexibility and thermal conductivity of HfC decorated carbon nanofiber mats

Future-generation spacecraft components allude discovery of novel materials that can withstand extreme environments (>2000 °C). The combined effect of ultra-high temperature ceramics (UHTCs) and carbon fibers (C f ) can satisfy the demanding requirements of aerospace applications. A novel, hybrid, and flexible hafnium carbide (HfC)-decorated carbon nanofiber (C nf ) mat was fabricated via electrospinning. Enhanced thermal stability of the flexible HfC decorated C nf over C nf can be elucidated from the 20-fold increment in thermal conductivity and the onset of degradation at higher temperatures (840 °C). Successful integration of multi-layered sandwich lattice using in-housed fabricated HfC decorated C nf showed retention of the fibrous structure even after extreme spark plasma sintering (SPS) process at 1850 °C. Fabricating a similar multi-layered structure using procured C f was unsuccessful due to bundled agglomeration and micron-sized fibers. High-load indentation suggests that HfC decorated C nf interlayer is stronger (~2.3 times) than the parent UHTC with no cracking at the interface. Compared with the HfC matrix, the indentation-damaged area at the interface reduced up to ~56% due to toughening mechanisms such as C nf , fiber pull-out and bridging. The synthesized HfC decorated Cnf mat is proposed as an ultra-thin filler material for joining similar or dissimilar UHTCs while maintaining similar chemistry and better mechanical integrity at the interface. Furthermore, the findings insinuate a new paradigm in designing hybrid and flexible ceramic-containing materials for thermal protection systems (TPS) of future-generation spacecraft components that can mitigate failure in extreme environments (>2000 °C).

36 MATERIALS SCIENCE↗
NASA NTRS2003

Thermal Management Coating As Thermal Protection System for Space Transportation System

This paper presents viewgraphs on the development of a non-ablative thermal management coating used as the thermal protection system material for space shuttle rocket boosters and other launch vehicles. The topics include: 1) Coating Study; 2) Aerothermal Testing; 3) Preconditioning Environments; 4) Test Observations; 5) Lightning Strike Test Panel; 6) Test Panel After Impact Testing; 7) Thermal Testing; and 8) Mechanical Testing.

Kaul, Raj↗
NASA NTRS2016

Cyanate Ester and Phthalonitrile Impregnated Carbon Ablative TPS

Phenolic resin has extensive heritage as a TPS (Thermal Protection Systems) material, however, alternative resin systems such as Cyanate Ester and Phthalonitrile may offer improved performance compared to state-of-the-art phenolic resin. These alternative resin systems may have higher char yield, higher char strength, lower thermal conductivity and improved mechanical properties. In current work at NASA Ames alternative resin systems were uniformly infused into fibrous substrates and preliminary properties characterized. The density of the cyanate ester infused in fibrous substrate ranged from 0.25-0.3 grams per cubic centimeter compared to PICA (Phenolic resin impregnated carbon ablative) having a density of approximately 0.25 grams per cubic centimeter. The density of Phthalonitrile varies from 0.22-0.25 grams per cubic centimeter. Initial formulations of these new resin systems were recently tested at the LARC HyMETs (Hypersonic Materials Environmental Test System) facility to evaluate their performance and data such as back face temperature, char yield, and recession are compared to PICA. Cyanate Ester and Phthalonitrile impregnated carbon ablative samples showed comparable performance to phenolic resin impregnated carbon ablative samples.

Polymer↗
NASA NTRS2017

Radiative Heat Transfer Modeling in Fibrous Porous Media

Phenolic-Impregnated Carbon Ablator (PICA) was developed at NASA Ames Research Center as a lightweight thermal protection system material for successful atmospheric entries. The objective of the current work is to compute the effective radiative conductivity of fibrous porous media, such as preforms used to make PICA, to enable the efficient design of materials that can meet the thermal performance goals of forthcoming space exploration missions.

Radiative↗
NASA NTRSDate not supplied

Understanding Thermal Stability in Zirconia-Based Aerogels

For lightweight, thermal insulation needs above 1000ºC, the high surface to volume ratios of ceramic-based aerogels are practically unparalleled. Yet realizing the full potential of aerogel-based thermal protection systems requires not only increased thermal stability, but also a broadened menu of stabilizing mechanisms. Here we will review our recent efforts to understand the impact of synthetic parameters and dopant chemistry on the evolution of zirconia-based ceramics. A broad parametric window for thermal stability is established, in which the more sensitive variable of composition has been probed. However, dopant chemistry is actually an aggregate for many closely related material parameters including surface energy, enthalpy of formation, each of which may contribute uniquely to aerogel destabilization. A truly predictive design framework for ceramic-based aerogels requires further decoupling of these underlying properties through systematic and comprehensive evaluation of thermodynamic properties.

aerogel↗
NASA NTRS2013

Parametric Thermal Soak Model for Earth Entry Vehicles

The analysis and design of an Earth Entry Vehicle (EEV) is multidisciplinary in nature, requiring the application many disciplines. An integrated tool called Multi Mission System Analysis for Planetary Entry Descent and Landing or M-SAPE is being developed as part of Entry Vehicle Technology project under In-Space Technology program. Integration of a multidisciplinary problem is a challenging task. Automation of the execution process and data transfer among disciplines can be accomplished to provide significant benefits. Thermal soak analysis and temperature predictions of various interior components of entry vehicle, including the impact foam and payload container are part of the solution that M-SAPE will offer to spacecraft designers. The present paper focuses on the thermal soak analysis of an entry vehicle design based on the Mars Sample Return entry vehicle geometry and discusses a technical approach to develop parametric models for thermal soak analysis that will be integrated into M-SAPE. One of the main objectives is to be able to identify the important parameters and to develop correlation coefficients so that, for a given trajectory, can estimate the peak payload temperature based on relevant trajectory parameters and vehicle geometry. The models are being developed for two primary thermal protection (TPS) materials: 1) carbon phenolic that was used for Galileo and Pioneer Venus probes and, 2) Phenolic Impregnated Carbon Ablator (PICA), TPS material for Mars Science Lab mission. Several representative trajectories were selected from a very large trade space to include in the thermal analysis in order to develop an effective parametric thermal soak model. The selected trajectories covered a wide range of heatload and heatflux combinations. Non-linear, fully transient, thermal finite element simulations were performed for the selected trajectories to generate the temperature histories at the interior of the vehicle. Figure 1 shows the finite element model that was used for the simulations. The results indicate that it takes several hours for the thermal energy to soak into the interior of the vehicle and achieve maximum payload temperatures. In addition, a strong correlation between the heatload and peak payload container temperature is observed that will help establishing the parametric thermal soak model.

Agrawal, Parul↗
NASA NTRSDate not supplied

Simulation of Dust-Laden Flow in the DLR L2K Facility

An integrated CFD-particle trajectory code called US3D-DUST is used to simulate the dusty flow environments performed in the German Aerospace Center (DLR) L2K arcjet facility. The particle trajectory code uses a Lagrangian approach, where the particle trajectories through the shock layer can be computed using a set of coupled ordinary differential equations. The L2K experiments measured mass loss to flat-face shaped samples of the Norcoat-Liège thermal protection system material. The US3D-DUST simulations were able to reproduce particle velocity and stagnation point heating rate data. When applied to the L2K dusty flow conditions, the US3D-DUST predictions of mass loss due to particle impacts and surface recession rates over-predicted the experimental values. It is recommended to perform additional dusty flow tests in the L2Kto provide and improve the surface damage model for Norcoat-Liège.

Thermal protection systems↗
NASA NTRS2011

Using FT-IR Spectroscopy to Elucidate the Structures of Ablative Polymers

The composition and structure of an ablative polymer has a multifaceted influence on its thermal, mechanical and ablative properties. Understanding the molecular level information is critical to the optimization of material performance because it helps to establish correlations with the macroscopic properties of the material, the so-called structure-property relationship. Moreover, accurate information of molecular structures is also essential to predict the thermal decomposition pathways as well as to identify decomposition species that are fundamentally important to modeling work. In this presentation, I will describe the use of infrared transmission spectroscopy (FT-IR) as a convenient tool to aid the discovery and development of thermal protection system materials.

Fan, Wendy↗
NASA NTRS2009

Status and Mission Applicability of NASA's In-Space Propulsion Technology Project

The In-Space Propulsion Technology (ISPT) project develops propulsion technologies that will enable or enhance NASA robotic science missions. Since 2001, the ISPT project developed and delivered products to assist technology infusion and quantify mission applicability and benefits through mission analysis and tools. These in-space propulsion technologies are applicable, and potentially enabling for flagship destinations currently under evaluation, as well as having broad applicability to future Discovery and New Frontiers mission solicitations. This paper provides status of the technology development, near-term mission benefits, applicability, and availability of in-space propulsion technologies in the areas of advanced chemical thrusters, electric propulsion, aerocapture, and systems analysis tools. The current chemical propulsion investment is on the high-temperature Advanced Material Bipropellant Rocket (AMBR) engine providing higher performance for lower cost. Investments in electric propulsion technologies focused on completing NASA's Evolutionary Xenon Thruster (NEXT) ion propulsion system, a 0.6-7 kW throttle-able gridded ion system, and the High Voltage Hall Accelerator (HiVHAC) thruster, which is a mid-term product specifically designed for a low-cost electric propulsion option. Aerocapture investments developed a family of thermal protections system materials and structures; guidance, navigation, and control models of blunt-body rigid aeroshells; atmospheric models for Earth, Titan, Mars and Venus; and models for aerothermal effects. In 2009 ISPT started the development of propulsion technologies that would enable future sample return missions. The paper describes the ISPT project's future focus on propulsion for sample return missions. The future technology development areas for ISPT is: Planetary Ascent Vehicles (PAV), with a Mars Ascent Vehicle (MAV) being the initial development focus; multi-mission technologies for Earth Entry Vehicles (MMEEV) needed for sample return missions from many different destinations; propulsion for Earth Return Vehicles (ERV), transfer stages to the destination, and Electric Propulsion for sample return and low cost missions; and Systems/Mission Analysis focused on sample return propulsion. The ISPT project is funded by NASA's Science Mission Directorate (SMD).

Anderson, David J.↗
NASA NTRSDate not supplied

Quantitative Characterization of 3D Woven Composites Via Fourier Analysis and Structure Tensors Applied to CT Scans

NASA's development of advanced 3D woven carbon composites, such as HEEET and 3MDCP, represents a significant leap in materials designed to endure extreme atmospheric entry conditions. However, the internal complexity of these materials introduces a variety of structures and novel defect types. Traditional characterization methods rely on labor-intensive, manual examination of X-ray CT scans, demanding considerable time and expertise. This process, while thorough, is not sustainable for large-scale analysis and defect tracking. Addressing this critical challenge, this presentation introduces an innovative suite of automated tools and analytical techniques, pioneered by the Mars Sample Return (MSR) Earth Entry System (EES) Thermal Protection System (TPS) project. These advancements offer a more efficient and accurate approach for quantifying CT data and characterizing the defects of 3D woven composites.

3D Woven↗
NASA NTRS2014

Remote Recession Sensing of Ablative Heat Shield Materials

Material recession and charring are two major processes determining the performance of ablative heat shield materials. Even in ground testing, the characterization of these two mechanisms relies on measurements of material thickness before and after testing, thus providing only information integrated over the test time. For recession measurements, optical methods such as imaging the sample surface during testing are under investigation but require high alignment and instrument effort, therefore being not established as a standard measurement method. For char depth measurements, the most common method so far consists in investigation of sectioned samples after testing or in the case of Stardust where core extractions were performed to determine char information. In flight, no reliable recession measurements are available, except total recession after recovering the heat shield on ground. Developments of mechanical recession sensors have been started but require substantial on board instrumentation adding mass and complexity. In this work, preliminary experiments to evaluate the feasibility of remote sensing of material recession and possibly char depth through optically observing the emission signatures of seeding materials in the post shock plasma is investigated. It is shown that this method can provide time resolved recession measurements without the necessity of accurate alignment procedures of the optical set-up and without any instrumentation on board of a spacecraft. Furthermore, recession data can be obtained without recovering flight hardware which would be a huge benefit for inexpensive heat shield material testing on board of small re-entry probes, e.g. on new micro-satellite re-entry probes as a possible future application of Cubesats or RBR

instrumentation↗