Ablative thermal protection at low heating rates.
Ablative materials thermal protection characteristics at low heating rates evaluated by convective heating tests, stressing polyurethane foam composite
Goldstein, H. E.↗
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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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Self-replaceable thermocouple for molten steel bath - A concept
Thermocouple wires, consisting of tungsten-rhenium alloy protected by ablative ceramic coating, are wound on a reel and fed continuously into bath. Tests indicate accuracy and reliability are comparable to conventional devices.
Blau, P.↗
Remote Optical Recession Measurement of Orion Thermal Protection System
For the Orion Multi-Purpose Crew Vehicle (MPCV) project, NASA is minimizing the use of onboard diagnostics, especially external sensors that penetrate the structure. Nonetheless, there is a desire to measure the Thermal Protection System (TPS) recession during reentry. One noninvasive technique currently under investigation is the insertion of indicator metals into the heatshield at varied depths and spatial locations. A remote (airborne) spectrometer detects the emissions from the ionized metal to reveal the time (thus depth) of the metal release. Innovative processing enables the emission features from trace amounts of the selected metals to be reliably detected against the complex and structured spectral background of the shock layer and ablated TPS material. The con-cept has been proven viable through ground testing at NASA HyMETS and AHF arc jet facilities using the Orion TPS material (Avcoat). This presentation highlights the parametric testing that was conducted to select the optimal indicator metals and to assess the accuracy of remote recession measurements using this technique. The CONOPS for integrating the technique into the Orion flight tests is also presented. This includes the onboard indicator metal "seeded plugs" and the offboard airborne sensor platform that would be deployed.
Scriven, Gordon↗
Ames Arc Jets in Support for Planetary Defense
Poster showing overview of the Arc Jet Complex, Past use for testing TPS materials for hypersonic entry, possible uses for planetary defense and understanding ablation of meteors at entry.
Fretter, Ernest↗
Effect of Phenolic Matrix Microcracking on the Structural Response of a 3-D Woven Thermal Protection System
The effect of microcracking in the phenolic matrix of a three-dimensional woven thermal protection system (TPS) and the resulting material stiffness reduction was studied via a comparison of finite element analysis results from a linear analysis and an iterative linear analysis. A TPS is necessary to protect space vehicles from the aerodynamic heating of planetary entry. The Heatshield for Extreme Entry Environment Technology (HEEET) project has developed a TPS for use in high heat-flux and pressure missions. The material is a dual-layer continuous dry weave, which is then infiltrated with a low-density phenolic resin matrix to form a rigid ablator. The phenolic resin matrix does not have structural load transfer requirements, and testing has shown that the phenolic resin can fully satisfy thermal requirements when the matrix contains microcracks. Due to high stresses in the through-the-thickness direction of the material, phenolic microcracks may form in the matrix material, which would result in a reduction of stiffness. An exploratory study was conducted to determine if reduction in material stiffness would change the load paths and/or decrease the structural margins. A comparison was performed between a linear finite element analysis that did not take into account phenolic microcracking and an iterative linear finite element analysis that accounted for propagation of phenolic microcracking. Four subcases using varying assumptions were analyzed and the results indicate that the assumed strength at which the phenolic microcracking propagates was the critical parameter for determining the extent of microcracking in the phenolic matrix. Phenolic microcracking does not have an adverse effect on the structural response of the test article and is not a critical failure.
Langston, Sarah L.↗
Ablative performance of uncoated silicone-modified and shuttle baseline reinforced carbon composites
The relative ablative performance of uncoated silicone-modified reinforced carbon composite (RCC) and uncoated shuttle baseline RCC substrates was investigated. The test specimens were 13 plies (5.3 to 5.8 millimeters) thick and had a 25-millimeter-diameter test face. Prior to arc tunnel testing, all specimens were subjected to a heat treatment simulating the RCC coating process. During arc tunnel testing, the specimens were exposed to cold wall heating rates of 178 to 529 kilowatts/sq m and stagnation pressures ranging from 0.015 to 0.046 atmosphere at Mach 4.6 in air, with and without preheating in nitrogen. The results show that the ablative performance of uncoated silicone-modified RCC substrates is significantly superior to that of uncoated shuttle baseline RCC substrates over the range of heating conditions used. These results indicate that the silicone-modified RCC substrate would yield a substantially greater safety margin in the event of complete coating loss on the shuttle orbiter.
Dicus, D. L.↗
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↗
Meteors do not break exogenous organic molecules into high yields of diatomics
Meteoroids that dominate the Earth's extraterrestrial mass influx (50-300 microm size range) may have contributed a unique blend of exogenous organic molecules at the time of the origin of life. Such meteoroids are so large that most of their mass is ablated in the Earth's atmosphere. In the process, organic molecules are decomposed and chemically altered to molecules differently from those delivered to the Earth's surface by smaller (<50 microm) micrometeorites and larger (>10 cm) meteorites. The question addressed here is whether the organic matter in these meteoroids is fully decomposed into atoms or diatomic compounds during ablation. If not, then the ablation products made available for prebiotic organic chemistry, and perhaps early biology, might have retained some memory of their astrophysical nature. To test this hypothesis we searched for CN emission in meteor spectra in an airborne experiment during the 2001 Leonid meteor storm. We found that the meteor's light-emitting air plasma, which included products of meteor ablation, contained less than 1 CN molecule for every 30 meteoric iron atoms. This contrasts sharply with the nitrogen/iron ratio of 1:1.2 in the solid matter of comet 1P/Halley. Unless the nitrogen content or the abundance of complex organic matter in the Leonid parent body, comet 55P/Tempel-Tuttle, differs from that in comet 1P/Halley, it appears that very little of that organic nitrogen decomposes into CN molecules during meteor ablation in the rarefied flow conditions that characterize the atmospheric entry of meteoroids approximately 50 microm-10 cm in size. We propose that the organics of such meteoroids survive instead as larger compounds.
Meteoroids↗
MEDLI2: Ablator Models for Flight
During the entry of Mars Science Laboratory (MSL) the heatshield was equipped with the instrumentation suite Mars Entry, Descent, and Landing Instruments (MEDLI). In-depth thermocouple (TC) data was used to reconstruct the surface heating[1,2]. Discrepancies between MEDLI’s flight heating data and predicted thermal response and recession[3] led to a campaign to characterize and test Mars2020 and MEDLI2 (Mars Entry, Descent, and Landing Instrument 2)[4] flight-lot thermal protection materials (TPS) at relevant ground test conditions. This paper covers the development and validation of flight-lot material response models for the heatshield material Phenolic Impregnated Carbon Ablator (PICA) and the backshell material SLA-561V (Super Lightweight Ablator). Virgin and char properties such as thermal conductivity and emissivity were updated as a function of temperature and pressure in the MEDLI2 specific material response models. Other material properties were characterized and determined to be similar to prior TPS material measurements used for the heritage models. MEDLI2 also investigated the impact of the protective coating that was applied to MSL and Mars2020’s PICA heatshield to reduce the particulate matter shedding. Evidence from arc jet experiments on coated PICA showed that although there were no adverse effects on the performance of the TPS, there were differences in the in-depth temperatures and reduced recession compared to material response predictions of uncoated PICA.[5,6]. Fully Implicit Ablation and Thermal response (FIAT)[7] material response simulations were conducted with the heritage and MEDLI2 flight-lot material models. FIAT-predicted in-depth temperature responses and recession predictions were compared to flight-lot certification ground-test arc jet test data and MEDLI2 thermocouple data.
Materials Response↗
Radiant Heating Tests on Meteoritic Material
A new effort geared toward modeling the physics of meteor entry and break-up is underway at NASA Ames Research Center. This is part of a broader interdisciplinary effort on providing physics-based risk assessment models for potentially hazardous objects. As part of the entry modeling task we are seeking to improve our understanding of, among other things, the ablation of meteoric material during high speed entry into earths atmosphere. Meteoroid entry differs greatly in some key respects from spacecraft entry modeling. First, the aerothermal environment at these high velocities (18 km/s) is dominated by radiation. Second, meteoroids less than, say, 50m in size, will likely lose a significant portion of their mass during the high-speed atmospheric entry process due to vaporization as well as melting and spallation. The mass of the object, in turn, directly affects the amount of energy deposited in the atmosphere, and therefore the amount of damage done. Thus it is important for us to understand and be able to model this process in greater detail in order to assess the hazard posed by these objects.In this presentation, we first give an overview of the simple ablation models that are typically used in meteor entry calculations. Additionally, we will present a new model which utilizes a similar approach to what is typically done for spacecraft TPS response modeling. This uses an equilibrium assumption near the surface to compute the ablation rate, as is done in heritage material response codes. Next we describe the radiant heating experiment which uses a high-powered laser to emulate the radiation dominated heating environment experienced by meteoroids during atmospheric entry. The facility the Laser Hardened Material Evaluation Laboratory (LHMEL) permits us to expose samples of meteoritic material to heating rates in excess of 100kW/sq.cm. An overview of the experimental set-up and test plan for the initial exploratory campaign at this facility will be given. Then we present both qualitative and quantitative results from this initial test series. Comparisons between predicted and measured ablation rates suggest that there may be significant blockage of the incident beam by the ablation plume. Furthermore, melt is shown to be a significant ablation mechanics, even at high heating rates (16 kW/sq.cm). Finally, comparisons between the phenomenology of the ablation of terrestrial rocks namely, basalt -- to that of meteorites show very different behavior. This is shown to likely be due in part to the effect of composition on the melt viscosity.
Stern, Eric↗
Phase 2 study of improved materials for use on Scout rocket motor nozzles
Nozzle material performance data were obtained, and the feasibility was determined of using new materials on the Scout rocket motor nozzles. Stress and heat transfer analyses were conducted to aid in the selection of optimum materials for nozzle tests. A reimpregnated and graphitized throat insert was fabricated along with two nozzles with ablative throats. The dissection and determining of char and erosion of two nozzles fired on X-259 loaded cases are discussed; one of the nozzles used a graphite phenolic ablative throat insert, and the other unit was a standard X-259 nozzle with a reduced area ATJ graphite throat insert.
Stutzman, R. D.↗
Ablative liner locates hotspots
Ablative liner quantifies local-heating effects in combustion chambers and other applications. By identifying hotspots and helping to map heat-flux patterns, liner is useful tool for research in engine design. Liner permanently records heat flux at each point by depth of ablation due to local heating. Technique determines best locations for thermocouples for more extensive testing.
Mercer, S. D.↗
The response of heat-shield materials to intense laser radiation
Experimental results for the response of ATJ graphite, Carbitex 100, and carbon phenolic to intense continuous-wave laser radiation are presented. Both penetration and mass-loss test techniques are used and compared. The results are also compared with a simple ablation theory applicable to laser irradiation. Reasons for the disparity between experiment and theory, and applicability of the results to other heating situations, such as planetary entry, are discussed.
Lundell, J. H.↗
An Overview of NASA's Current Materials Development Efforts for Mars EDL
Current roadmaps point to landing heavy masses (cargo, followed by manned vehicles) on Mars in the 2030's and the existing entry, descent and landing (EDL) technology will not be sufficient to facilitate such missions. In 2009 the Exploration Technology Development Program (ETDP) established the Entry, Descent and Landing Technology Development Project (EDL TDP), to be managed programmatically at Langley Research Center (LaRC) and technically a Ames Research Center (ARC). The purpose of the project is to further the technologies required to land heavy (approximately 40 metric ton) masses on Mars to facilitate exploration. The EDL TDP contains three technical elements. They are: 1) Thermal Protection Systems (TPS) development 2) Modeling and Tools (MAT) development 3) Supersonic Retropropulsion (SRP) development The primary goals of the EDL TDP TPS element is to design and develop TPS materials capable of withstanding the severe aerothermal loads associated with aerocapture and entry into the Martian atmosphere while significantly decreasing the TPS mass fraction contribution to the entry system. Significant advancements in TPS materials technology are needed in order to enable heavy mass payloads to be successfully landed on the Martian surface for robotic precursors and subsequent human exploration missions. The EDL TDP TPS element is further divided into two different TPS concepts for Mars EDL those being: 1) Rigid TPS for a mid L/D aeroshell with the capability to withstand dual pulsed heating environments as high as 500 W/square cm for aerocapture and 130 W/square cm for entry 2) Flexible TPS for a deployable aerodynamic decelerator with the capability to withstand dual pulsed heating environments as high as 120 W/square cm for aerocapture and 30 W/square cm for entry NASA, along with its vendors, has begun developing and testing materials for each of the deceleration approaches. These include multi-layer rigid ablators and flexible ablative materials. In order to model the response of these types of materials, new and improved modeling techniques will be required. This presentation will outline the types of materials that are under development and illustrate the need for advancement in modeling of ablative materials.
Beck, Robin A.↗
TPSAS-NF1676L-18873-DND
The potential formation of α-case that was initially raised by metallurgists has been addressed at the micron scale. Mechanical fatigue testing is needed in the Phase II to demonstrate durability. X-Ray Photoelectron Spectroscopy (XPS) characterization indicated that detrimental hydroxyl species are removed by laser ablation, mil scale is efficiently stripped, and fresh (beneficial) oxides are readily formed at higher laser ablation energies. XPS has established that no detrimental chemistry is being produced by the laser treatment. A technique was developed to aid in failure mode analysis. Adhesion studies conducted with two test methods and two adhesives have indicated that a stable interface is formed.
Frank L Palmieri↗
Development and Optical Testing of the Camera, Hand Lens, and Microscope Probe with Scannable Laser Spectroscopy (CHAMP-SLS)
Conducting high resolution field microscopy with coupled laser spectroscopy that can be used to selectively analyze the surface chemistry of individual pixels in a scene is an enabling capability for next generation robotic and manned spaceflight missions, civil, and military applications. In the laboratory, we use a range of imaging and surface preparation tools that provide us with in-focus images, context imaging for identifying features that we want to investigate at high magnification, and surface-optical coupling that allows us to apply optical spectroscopic analysis techniques for analyzing surface chemistry particularly at high magnifications. The camera, hand lens, and microscope probe with scannable laser spectroscopy (CHAMP-SLS) is an imaging/spectroscopy instrument capable of imaging continuously from infinity down to high resolution microscopy (resolution of approx. 1 micron/pixel in a final camera format), the closer CHAMP-SLS is placed to a feature, the higher the resultant magnification. At hand lens to microscopic magnifications, the imaged scene can be selectively interrogated with point spectroscopic techniques such as Raman spectroscopy, microscopic Laser Induced Breakdown Spectroscopy (micro-LIBS), laser ablation mass-spectrometry, Fluorescence spectroscopy, and/or Reflectance spectroscopy. This paper summarizes the optical design, development, and testing of the CHAMP-SLS optics.
Fluorescence↗
Overview of Ablative TPS Modeling at NASA Ames
Over the past decade, NASA has invested in efforts to build predictive thermal protection system (TPS) material models from the micro-scale to the macro-scale. To complement the mission design cycle process and reduce the need for extensive testing, NASA is developing modeling and simulation tools that enable characterizing material properties and response to hot plasma experienced during atmospheric entry. Traditional material response and ablation modeling tools, such as the heritage code FIAT, and its multidimensional siblings, TITAN and 3dFIAT, are being complemented with newly developed software such as Icarus and PATO. Both of these programs are three-dimensional, finite-volume solvers that use unstructured meshes and 21st century programming paradigms to allow for efficient parallel simulations. FIAT and Icarus are also used for TPS sizing purposes. Today, these traditional tools are being supplemented with computational materials models at the atomistic level. The scales of interest range from computational chemistry (Density Functional Theory [DFT]), to atomistic simulations (Molecular Dynamics [MD]), to the microscale with the Porous Microstructure Analysis (PuMA) software that was recently awarded the 2022 NASA Software of the Year award. Finally, thermo-structural modeling is also of interest to the TPS Materials branch and done using commercial tools such as MSC MARC, MENTAT, NASTRAN and PATRAN. The present talk will also link the use of these computational tools to current NASA missions and projects associated with challenging and complex vehicles entries/reentries.
materials modeling↗
Task 4 supporting technology. Part 1: Detailed test plan for leading edge tile development. Leading edge material development and testing
This task develops two alternative candidate tile materials for leading edge applications: coated alumina enhanced thermal barrier (AETB) tile and silicone impregnated reusable ceramic ablator (SIRCA) tile. Upon reentry of the X-33/RLV space vehicle, the leading edges experience the highest heating rates and temperatures. The wing leading edge and nose cap experience peak temperatures in the range 2000 to 2700 F. Replacing reinforced carbon-carbon (RCC) with tile-based thermal protection system (TPS) materials is the primary objective. Weight, complexity, coating impact damage, and repairability are among the problems that this tile technology development addresses. The following subtasks will be performed in this development effort: tile coating development; SIRCA tile development; robustness testing of tiles; tile repair development; tile operations/processing; tile leading edge configuration; and life cycle testing.
Hogenson, P. A.↗