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NASA NTRS1996

PICA Forebody Heatshield Qualification for the Stardust Discovery Class Mission

This paper presents the qualification of the light weight Phenolic Impregnated Carbon Ablators (PICA) as the forebody heatshield for the Stardust Discovery Class Mission. The Stardust spacecraft will be launched in early 1999 and fly by Comet Wild-2 to collect cometary and interstellar dust and return them back to earth in the Sample Return Capsule (SRC). This earth re-entry will be the fastest to date, at 12.6 km/s, and therefore requires a heatshield that can withstand very high heating rates and stagnation pressures, as well as provide the necessary insulation to the vehicle structure. The PICA material was developed as part of the Lightweight Ceramic Ablators program at NASA Ames Research Center, and was baselined as the forebody heatshield because of its low density and superior ablation and thermal performance at severe aerothermodynamic conditions. Under a Small Business Innovative Research (SBIR) program with NASA Ames, Fiber Materials, Inc. developed a process to manufacture a single-piece PICA heatshield for the forebody of the SRC, along with witness material for the fabrication of the test models. The test models were fabricated and instrumented by the staff of Lockheed Martin Astronautics in Denver, Colorado. Full body preliminary aerothermal CFD calculations were performed at NASA Ames to determine the heating and stagnation pressure conditions. The Heat shield sizing was also performed at NASA Ames by using a new material response code that accounts for the highly porous characteristics of the PICA material. The ablation and thermal performance of PICA was qualified in the NASA Ames Interaction Heating Arc Jet Facility. A total of 24 models and four test conditions were used to qualify PICA at the predicted peak heat flux, heat load, shear, and stagnation pressure conditions. Surface and in-depth temperatures were measured using optical pyrometers and thermocouples. Surface recession was measured by using a template and a height gage. Several models were tested to evaluate repair procedures, and two models were cold soaked in liquid nitrogen, prior th testing, to investigate the effect of the cold space environment on the performance of the material. In addition, material cored from a demonstration single-piece heatshield was tested to verify that the PICA process can be successfully completed on a large, complex heatshield shape.

Tran, Huy K.↗

NASA NTRS2018

Sustaining PICA TPS for Future NASA Robotic Science Missions

Phenolic Impregnated Carbon Ablator (PICA), invented in the mid 1990's, is a low-density ablative thermal protection material proven capable of meeting sample return mission needs from the moon, asteroids, comets and other "unrestricted class V destinations" as well as for Mars. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flagship class missions. It is important that NASA maintain this TPS material capability and ensure its availability for future NASA use. The rayon based carbon precursor raw material used in PICA preform manufacturing required replacement and requalification at least twice in the past 25 years and a third substitution is now needed. The carbon precursor replacement challenge is twofold â€“ the first involves finding a long-term replacement for the current rayon and the second is to assess its future availability periodically to ensure it is sustainable and be alerted if additional replacement efforts need to be initiated. Rayon is no longer a viable process in the US and Europe due to environmental concerns. In the early 80's rayon producers began investigating a new method of producing a cellulosic fiber through a more environmentally responsible process. This cellulosic fiber, lyocell, is a viable replacement precursor for PICA fiberform. This presentation reviews current SMD-PSD funded PICA sustainability activities in ensuring a rayon replacement for the long term is identified and in establishing that the capability of the new PICA derived from an alternative precursor is in family with previous versions of the so called "heritage" PICA.State of the Art Low Density Carbon Phenolic AblatorsStardust SRC post flight withPICA forebody heat shield(0.8m max. diameter)PICA Processing StepsRole of Rayon/Lyocellin PICA.

Stackpoole, Mairead↗

NASA NTRS2019

Progress Towards Modeling the Mars Science Laboratory PICA-NuSil Heatshield

The data collected by the Mars Science Laboratory (MSL) Entry, Descent and Landing Instrumentation, MEDLI, have become an established reference to assess the performance of engineering models of the Phenolic Impregnated Carbon Ablator (PICA) and to validate hypersonic computational fluid dynamics (CFD) tools for entry systems. MEDLI measurements are also extensively used as validation reference for current developments of high-fidelity material response models for PICA. So large has been the scientific output and impact of MEDLI that a follow-up instrumentation suite MEDLI2 is underway for the upcoming Mars 2020 mission.A feature neglected thus far in the modeling of the MSL heatshield, is the presence of a silicone-based room temperature vulcanizing coating designated NuSil CV-1144-0. NuSil was used to coat the entire MSL heatshield, including the MEDLI plugs, to mitigate the spread of phenolic dust from PICA, and limit contamination during clean room operations. NuSil CV-1144-0 is a space grade siloxane copolymer, designed as an oxygen protection barrier for extreme low temperature environment.Assessments conducted during MSL development demonstrated that the presence of NuSil had no adverse effect on the performance of PICA. However, evidence from ground testing of PICA-NuSil (PICA-N) models in the HyMETS arc-jet test facility suggests that the silicone changes the high temperature response of PICA. It is therefore critical to assess the importance of modeling the coating in ongoing code validation efforts.

Bessire, Brody K.↗

NASA NTRS2019

Progress Towards Modeling the Ablation Response of NuSil-Coated PICA

The Mars Science Laboratory (MSL) Entry, Descent and Landing Instrumentation (MEDLI) collected in-flight data largely used by the ablation community to verify and validate physics-based models for the response of the Phenolic Impregnated Carbon Ablator (PICA) material [1-4]. MEDLI data were recently used to guide the development of NASA’s high-fidelity material response models for PICA, implemented in the Porous material Analysis Toolbox based on OpenFOAM (PATO) software [5-6]. A follow-up instrumentation suite, MEDLI2, is planned for the upcoming Mars 2020 mission [7] after the large scientific impact of MEDLI. Recent analyses performed as part of MEDLI2 development draw the attention to significant effects of a protective coating to the aerothermal response of PICA. NuSil, a silicone-based overcoat sprayed onto the MSL heatshield as contamination control, is currently neglected in PICA ablation models. To mitigate the spread of phenolic dust from PICA, NuSil was applied to the entire MSL heatshield, including the MEDLI plugs. NuSil is a space grade designation of the siloxane copolymer, primarily used to protect against atomic oxygen erosion in the Low Earth Orbit environment. Ground testing of PICA-NuSil (PICA-N) models all exhibited surface temperature jumps of the order of 200 K due to oxide scale formation and subsequent NuSil burn-off. It is therefore critical to include a model for the aerothermal response of the coating in ongoing code development and validation efforts.

Meurisse, Jeremie B.↗

NASA NTRSDate not supplied

Heat Flux and Pressure Envelope Expansion Tests of Phenolic Impregnated Carbon Ablator (PICA)

Phenolic Impregnated Carbon Ablator (PICA) is a frequently employed thermal protection system (TPS) material in the space flight community. First flown on the forebody of Stardust, which re-entered in January of 2006, PICA has been the go-to material system for each successive Martian rover mission. This legacy continues with PICA domestic (PICA-D) baselined for the Mars Sample Retrieval Lander (SRL) and Dragon-fly, a mission to Titan’s surface. In mission planning, the capability of a TPS material system is restricted to environments that are proven through ground testing or flight missions. De-spite the range of destinations from Earth return to Mars entry to Saturn moons, PICA’s demonstrated capability currently covers heating rates less than 1800 W/cm2 and surface pressures less than 150 kPa [1]. These recognized limitations prevent PICA for consideration in direct entry applications at Venus, the outer planets, and high mass return missions at Earth, thus requiring selecting higher density materials [2].

PICA Arc-jet Testing Envelope↗

NASA NTRS2019

Thermal Protection System Technology Maturation and Sustainment in Support of In-situ Science Missions: HEEET and PICA

Among the challenges faced by the Entry Descent and Landing (EDL) community have been: the lack of a matured forebody heatshield thermal protection system (TPS) capable of meeting the demanding entry environments for the high priority in-situ science missions identified in the decadal survey at Venus, Saturn and the Ice Giants, and the continued sustainment of thermal protection systems/materials. In response to the identified shortfall in TPS technologies capable of extreme entry environments NASA's Space Technology Mission Directorate (STMD) and Science Mission Directorate (SMD) initiated the Heatshield for Extreme Entry Environment Technology (HEEET) project which has matured a 3D-Woven TPS to Technology Readiness Level 6 and which is ready for infusion into these high priority missions. During the development of HEEET long term sustainability was a key consideration. However existing TPS also continue to face sustainability issues. Phenolic Impregnated Carbon Ablator (PICA) has been/is being utilized by many SMD Missions (Stardust, Mars Science Laboratory, OSIRIS-Rex, Mars 2020, Dragonfly) and is under consideration for others including Mars Sample Return, so maintaining PICA for the long term is a priority for NASA. This presentation will discuss raw material sustainability challenges faced by PICA and the efforts by NASA to work with Fiber Materials Inc (FMI) to resolve these challenges with a more sustainable supply chain. In addition, NASA is working with FMI to increase the manufacturing scale for single piece PICA heatshields and to expand the aerothermal performance envelop maturing PICA for larger sized heatshield and more aggressive entry environments. This presentation will also identify challenges and limitations with these systems, particularly around understanding failure modes in these materials and systems and how understanding these may allow use of these systems in environments that are difficult to achieve in ground based testing.

Heatshield for Extreme Entry Environment Technolog↗

NASA NTRS2019

Thermal Protection System Technology Maturation and Sustainment in Support of In Situ Science Missions: HEEET and PICA

Challenges faced by the Entry Descent and Landing (EDL) community include the lack of a matured forebody heatshield thermal protection system (TPS) capable of meeting the demanding entry environments for the high priority in-situ science missions identified in the decadal survey at Venus, Saturn and the Ice Giants, and the continued sustainment of thermal protection systems/materials. In response to the identified shortfall in TPS technologies capable of extreme entry environments NASA's Space Technology Mission Directorate (STMD) and Science Mission Directorate (SMD) initiated the Heatshield for Extreme Entry Environment Technology (HEEET) project which has matured a 3D-Woven TPS to Technology Readiness Level 6 and which is ready for infusion into these high priority missions. During the development of HEEET long term sustainability was a key consideration. However existing TPS also continue to face sustainability issues. Phenolic Impregnated Carbon Ablator (PICA) has been/is being utilized by many SMD Missions (Stardust, Mars Science Laboratory, OSIRIS-Rex, Mars 2020, Dragonfly) and is under consideration for others including Mars Sample Return, so maintaining PICA for the long term is a priority for NASA. This presentation will discuss raw material sustainability challenges faced by PICA and the efforts by NASA to work with Fiber Materials Inc (FMI) to resolve these challenges with a more sustainable supply chain. In addition, NASA is working with FMI to increase the manufacturing scale for single piece PICA heatshields and to expand the aerothermal performance envelop maturing PICA for larger sized heatshield and more aggressive entry environments. This presentation will also identify challenges and limitations with these systems, particularly around understanding failure modes in these materials and systems and how understanding these may allow use of these systems in environments that are difficult to achieve in ground based testing

Phenolic Impregnated Carbon Ablator (PICA)↗

NASA NTRSDate not supplied

Material Response Analysis of PICA-NuSil at the Hypersonic Materials Environmental Test System

Phenolic impregnated carbon ablator (PICA) is a thermal protection system (TPS) that gained heritage during the Stardust mission and is the baseline TPS material for expeditions to Mars (e.g., Mars Science Laboratory and Mars 2020).1 PICA is friable; therefore, a polysiloxane resin (NuSil CV-1144-0) is deposited onto the surface of flight hardware before assembly, test, and launch operations (ATLO) to mitigate particle shedding. Furthermore, the Mars Science Laboratory (MSL) and Mars 2020 heatshields were instrumented with an array of thermocouple plugs (MEDLI Integrated Sensor Plugs or MISP) designed to measure the in-depth thermal response of PICA during flight. Post-flight analysis of MISP data suggests that recession was lower than predicted, and NuSil is suspected as a reasonable cause. NuSil primarily consists of a copolymer blend of dimethyl and diphenyl-substituted polysiloxane resin. Four decades of research in the field of polymer-derived ceramics demonstrate that polysiloxane resins form oxidation-resistant silicon oxycarbide materials at pyrolysis temperatures as low as 800 °C. -2 Furthermore, silicon oxycarbide materials exhibit excellent thermal stability at relatively high-temperatures (< 1200 °C) but eventually decompose via carbothermal reduction. -3 Therefore, it is reasonable to suggest that NuSil forms an oxidation-resistant thermal barrier coating on the TPS surface and influences the material response during atmospheric entry. Evidence for this notion was observed during prior arc-jet testing at both the Aerodynamic Heating Facility (AHF) and the Panel Test Facility (PTF) at the NASA Ames Research Center. Articles of PICA were subjected to testing in airflow, and a temperature discontinuity was recorded at the surface of coupons coated with NuSil. A glassy coating was observed to form at the surface in shear flow configurations (wedge and panel) under moderate heat fluxes. Furthermore, state-of-the-art material response models have yet to account for the underlying physics and chemistry of the temperature discontinuity. To this end, a pathfinder test campaign was executed at the Hypersonic Materials Environmental Test System (HyMETS) to enhance the fundamental understanding of PICA-NuSil ablation phenomena and provide a preliminary data set to aid in the development of material response models.

PICA↗

NASA NTRS2009

Thermal-Structural Analysis of PICA Tiles for Solar Tower Test

Thermal protection materials used in spacecraft heatshields are subjected to severe thermal and mechanical loading environments during re-entry into earth atmosphere. In order to investigate the reliability of PICA tiles in the presence of high thermal gradients as well as mechanical loads, the authors designed and conducted solar-tower tests. This paper presents the design and analysis work for this tests series. Coupled non-linear thermal-mechanical finite element analyses was conducted to estimate in-depth temperature distribution and stress contours for various cases. The first set of analyses performed on isolated PICA tile showed that stresses generated during the tests were below the PICA allowable limit and should not lead to any catastrophic failure during the test. The tests results were consistent with analytical predictions. The temperature distribution and magnitude of the measured strains were also consistent with predicted values. The second test series is designed to test the arrayed PICA tiles with various gap-filler materials. A nonlinear contact method is used to model the complex geometry with various tiles. The analyses for these coupons predict the stress contours in PICA and inside gap fillers. Suitable mechanical loads for this architecture will be predicted, which can be applied during the test to exceed the allowable limits and demonstrate failure modes. Thermocouple and strain-gauge data obtained from the solar tower tests will be used for subsequent analyses and validation of FEM models.

Agrawal, Parul↗

NASA NTRS2010

Examination of Scanning Electron Microscope and Computed Tomography Images of PICA

Micrographs of PICA (Phenolic Impregnated Carbon Ablator) taken using a Scanning Electron Microscope (SEM) and 3D images taken with a Computed Tomography (CT) system are examined. PICA is a carbon fiber based composite (Fiberform ) with a phenolic polymer matrix. The micrographs are taken at different surface depths and at different magnifications in a sample after arc jet testing and show different levels of oxidative removal of the charred matrix (Figs 1 though 13). CT scans, courtesy of Xradia, Inc. of Concord CA, were captured for samples of virgin PICA, charred PICA and raw Fiberform (Fig. 14). We use these images to calculate the thermal conductivity (TC) of these materials using correlation function (CF) methods. CF methods give a mathematical description of how one material is embedded in another and is thus ideally suited for modeling composites like PICA. We will evaluate how the TC of the materials changes as a function of surface depth. This work is in collaboration with ETH-Zurich, which has expertise in high temperature materials and TC modeling (including CF methods).

Lawson, John W.↗

NASA NTRS2019

Development of Lyocell Based Phenolic Impregnated Carbon Ablators (PICA-D) for Future 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 1999. Due to the obsolescence of the input fiber source, new PICA materials were developed using Lyocell, a domestic rayon fiber source. Results are presented from this effort. Manufacturing included fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet testing have been conducted. Initial testing indicates comparable performance with respect to heritage PICA material, and likely "drop-in" replacement for future NASA mission needs.

Thermal Protection↗

NASA NTRS2019

Development of Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future NASA Missions

thermal protection↗

NASA NTRS2019

Sustaining Phenolic Impregnated Carbon Ablator (PICA) for Future NASA Missions Including Discovery and New Frontiers

Phenolic Impregnated Carbon Ablator (PICA) was invented in the mid 1990's and due to its relatively low density and efficient performance has been the heat shield TPS of choice for a range of missions includ-ing, Stardust, OSIRIS-Rex, Mars Science Laboratry (MSL) and Mars 2020. PICA has also been the TPS solution on numerous Discovery and New Frontiers proposals, as both the heat shield and back shell TPS and is under consideration as both for the Mars Sample Return Earth Entry Vehicle (EEV) and the heat shield on the Sample Retrieval Lander (SRL). Recently NASA's Science Mission Directorate (SMD) has funded an activity to develop a more sus-tainable version of PICA and to expand the demon-strated capabilities of PICA both in manufacturing and aerothermal performance.

Thermal Protection Material↗

NASA NTRS2009

Arcjet Tests of Different Gap-Filler Options for the Orion PICA Heatshield

PICA (Phenolic Infiltrated Carbon Ablator) is one of the candidate thermal protection materials for the Orion vehicle. Because PICA is fabricated in blocks, gaps exist between the blocks, similar to the individual ceramic tiles of the Shuttle thermal protection system. The results of this work focus on arcjet test results of different gap-filler options for PICA, performed as part of the Orion TPS Advanced Development Project. The arcjet tests were performed at NASA Ames Research Center on stagnation models 4 inches in diameter at conditions representative of Orion flight conditions for both Lunar and Low Earth Orbit return. Performance of gap-filler options was evaluated based on the extent of backface temperature change, as compared to PICA without gaps, and on the extent of flow penetration into the gap, evident from the gap opening and widening.

Skokova, Kristina↗

NASA NTRS2010

Radiation Testing of PICA at the Solar Power Tower

Sandia National Laboratory's Solar Power Tower was used to irradiate specimens of Phenolic Impregnated Carbon Ablator (PICA), in order to evaluate whether this thermal protection system material responded differently to potential shock layer radiative heating than to convective heating. Tests were run at 50, 100 and 150 Watts per square centimeter levels of concentrated solar radiation. Experimental results are presented both from spectral measurements on 1- 10 mm thick specimens of PICA, as well as from in-depth temperature measurements on instrumented thicker test specimens. Both spectral measurements and measured in-depth temperature profiles showed that, although it is a porous, low-density material, PICA does not exhibit problematic transparency to the tested high levels of NIR radiation, for all pragmatic cm-to-inch scale thicknesses. PICA acted as a surface absorber to efficiently absorb the incident visible and near infrared incident radiation in the top 2 millimeter layer in the Solar Power Tower tests up to 150 Watts per square centimeter.

White, Susan M.↗

NASA NTRS2010

Radiation Testing of PICA at the Solar Power Tower

White, Susan↗

NASA NTRS2011

PICA Variants with Improved Mechanical Properties

Phenolic Impregnated Carbon Ablator (PICA) is a member of the family of Lightweight Ceramic Ablators (LCAs) and was developed at NASA Ames Research Center as a thermal protection system (TPS) material for the Stardust mission probe that entered the Earth s atmosphere faster than any other probe or vehicle to date. PICA, carbon fiberform base and phenolic polymer, shows excellent thermal insulative properties at heating rates from about 250 W/sq cm to 1000 W/sq cm. The density of standard PICA - 0.26 g/cu cm to 0.28 g/cu cm - can be changed by changing the concentration of the phenolic resin. By adding polymers to the phenolic resin before curing it is possible to significantly improve the mechanical properties of PICA without significantly increasing the density.

Thornton, Jeremy↗

NASA NTRS2016

Investigation of Performance Envelope for Phenolic Impregnated Carbon Ablator (PICA)

The present work provides the results of a short exploratory study on the performance of Phenolic Impregnated Carbon Ablator, or PICA, at high heat flux and pressure in an arcjet facility at NASA Ames Research Center. The primary objective of the study was to explore the thermal response of PICA at cold-wall heat fluxes well in excess of 1500 W/cm (exp 2). Based on the results of a series of flow simulations, multiple PICA samples were tested at an estimated cold wall heat flux and stagnation pressure of 1800 W/cm (exp 2) and 130 kPa, respectively. All samples survived the test, and no failure was observed either during or after the exposure. The results indicate that PICA has a potential to perform well at environments with significantly higher heat flux and pressure than it has currently been flown.

Ablative Material↗