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Adaptive finite element analysis of hypersonic laminar flows for aerothermal load predictions

The use of an adaptive mesh refinement procedure for analyzing hypersonic laminar flows with application to aerothermal load predictions is described. The adaptation procedure, which uses both quadrilateral and triangular elements, is implemented with the multistep Galerkin-Runge-Kutta scheme. Elements that lie in regions of strong gradients are refined based on indicators to obtain better definition of flow features. The effectiveness of the adaptive procedure is demonstrated by modeling Mach 11.7 flow over a 15-deg ramp. Numerical results are compared with predictions of strong interaction theories and experimental data. Surface quantities such as heating rates and pressure loads, critical for the effective design of high-speed vehicles, are found to be in good agreement with experimental values.

Ramakrishnan, R.↗

Integrated Thermal Protection Systems and Heat Resistant Structures

In the early stages of NASA's Exploration Initiative, Snecma Propulsion Solide was funded under the Exploration Systems Research & Technology program to develop a CMC heatshield, a deployable decelerator, and an ablative heat shield for reentry vehicles. Due to changes within NASA's Exploration Initiative, this task was cancelled in early FY06. This paper will give an overview of the work that was accomplished prior to cancellation. The Snecma team consisted of MT Aerospace, Germany, and Materials Research & Design (MR&D), NASA Langley, NASA Dryden, and NASA Ames in the United States. An Apollo-type capsule was chosen as the reference vehicle for the work. NASA Langley generated the trajectory and aerothermal loads. Snecma and MT Aerospace began the design of a ceramic aft heatshield (CAS) utilizing C/SiC panels as the capsule heatshield. MR&D led the design of a C/SiC deployable decelerator, NASA Ames led the characterization of several ablators, NASA Dryden led the development of a heath management system and the high temperature structures testing, and NASA Langley led the insulation characterization. Though the task was pre-maturely cancelled, a significant quantity of work was accomplished.

Pichon, Thierry↗

Thermal and aerothermal performance of a titanium multiwall thermal protection system

A metallic thermal protection system (TPS) concept the multiwall designed for temperature and pressure at Shuttle body point 3140 where the maximum surface temperature is approximately 811 K was tested to evaluate thermal performance and structural integrity. A two tile model of titanium multiwall and a model consisting of a low temperature reusable surface insulation (LRSI) tiles were exposed to 25 simulated thermal and pressure Shuttle entry missions. The two systems performed the same, and neither system deteriorated during the tests. It is indicated that redesign of the multiwall tiles reduces tile thickness and/or weight. A nine tile model of titanium multiwal was tested for radiant heating and aerothermodynamics. Minor design changes that improve structural integrity without having a significant impact on the thermal protection ability of the titanium multiwall TPS are identified. The capability of a titanium multiwall thermal protection system to protect an aluminum surface during a Shuttle type entry trajectory at locations on the vehicle where the maximum surface temperature is below 811 K is demonstrated.

Avery, D. E.↗

Laminar and turbulent flow computations of Type 4 shock-shock interference aerothermal loads using unstructured grids

This report presents computations for the Type 4 shock-shock interference flow under laminar and turbulent conditions using unstructured grids. Mesh adaptation was accomplished by remeshing, refinement, and mesh movement. Two two-equation turbulence models were used to analyze turbulent flows. The mean flow governing equations and the turbulence governing equations are solved in a coupled manner. The solution algorithm and the details pertaining to its implementation on unstructured grids are described. Computations were performed at two different freestream Reynolds numbers at a freestream Mach number of 11. Effects of the variation in the impinging shock location are studied. The comparison of the results in terms of wall heat flux and wall pressure distributions is presented.

Vemaganti, Gururaja R.↗

Coupling CFD and Material Response for Analysis of Mars Entry

In computing the response of an ablating thermal protection system during atmospheric entry, the aerothermal environment and material response are generally computed separately with a blowing correction term in the material response model to account for the blowing of char and pyrolysis gases. In this work, we apply a coupled approach in which pyrolysis blowing gases, computed in the PATO material response code, are used with a blowing boundary condition in the DPLR hypersonic CFD code. This leads to an iterative method in which blowing products from PATO are input into DPLR to update surface heating estimates. The full iterative method, with the addition of radiative heating estimates using the NEQAIR radiation solver, is shown in Fig. 1. The method is demonstrated on a sphere case with the environment and material properties based on the Mars Science Laboratory entry. Future work includes utilizing this method in computing full 3D material response during the Mars 2020 entry.

Ablation↗

Trajectory Engineering with Modular Patched Conics for Entry Systems and TPS (TEMPEST)

Brief Presenter Biography (35 word limit): Bohdan Wesely is an Aerospace Engineer in the Entry Systems and Technology Division at Ames. He has worked on a variety of projects for NASA including integrated TPS (thermal protection system) flight hardware deliveries and testing services for commercial partners. Introduction: TEMPEST is a new trajectory analysis framework that is designed to fill the gap between dedicated flight mechanics tools and aerothermal and TPS sizing tools. The project started as an SJSU master’s thesis and has since evolved into a general conceptual design tool capable of studying a wide variety of entry problems. Development is ongoing in the Entry Systems and Technology Division at NASA ARC. Why TEMPEST: Space missions involving entry into a planetary atmosphere involve a series of unique requirements across multiple disciplines. Whether it is traditional entry descent and landing (EDL), or aerocapture, the vehicle must navigate to its target landing location or orbit state, and the TPS must protect the payload during entry. The design process typically involves iterative handoffs between various flight mechanics, flow solver, and material response level tools. During the early conceptual phase, a wide variety of feasible trajectories are simulated in a Monte Carlo scenario which broadly satisfy the mission or landing requirements. Next, computational fluid dynamics (CFD), direct simulation Monte Carlo (DSMC), and other flow solver analyses are performed at various key trajectory points to generate an aero-database, heating and TPS design requirements also emerge at this stage. At this point, with updated aerodynamics from the various flow solvers, trajectories can be re-run, this in turn can change the required freestream conditions for the CFD tools, and as a project progresses, these analyses converge, and uncertainty is reduced. However, there is always a “hand-off” occurring between two inherently coupled phenomena. Analysis Description: One of the goals with TEMPEST is to use a variety of first principles estimation methods coupled with an atmosphere model to predict vehicle aerothermodynamics across the entire flight regime while propagating a 3 or 6 degree of freedom (DoF) trajectory. Aerodynamics methods include modified Newtonian, Maxwell and Cercignani- Lampis-Lord (CLL) for continuum, transitional, and free molecular flow regimes. Aerothermodynamics include boundary layer and reference enthalpy methods, and Mutation++ for non-equilibrium chemistry modeling. TEMPEST is also capable of stitching multiple trajectory segments together to study mission scenarios like multi-pass aerocapture and aero-gravity assists. Most of the program is implemented in MATLAB using modern system objects, it relies on several C++ shared libraries for supporting tools like Gmsh, the Global Reference Atmospheric Model (GRAM), and Mutation++. The various first principles aerothermal estimation methods are discretized across either a structured axisymmetric panel mesh or an unstructured tri-mesh generated from an open-source tool such as Gmsh, this allows solutions on the same mesh to be compared across tools such as CB-Aero. CFD Coupling. A physics-aware, gaussian process CFD anchoring scheme is proposed to adjust the various first principles methods as a CFD database is populated. One goal for this anchoring module is to inform the project where CFD should be run. Full knowledge of the entire trajectory, atmosphere, and aerothermodynamics allows for easier identification of high sensitivity areas and uncertainty quantification. While the first principles effects are well known and proven accurate in existing tools such as CB- Aero and Cart3D, a physics aware CFD anchoring scheme increases tool credibility across a project lifecycle. Material Response Modeling. Correct TPS sizing is critical for optimizing mass for science payloads and ensuring mission success. The process typically involves a thermal analysis along the trajectory with surface heating environments as a boundary condition. Several design constraints are maximum bondline temperature and maximum recession with various margining techniques. The material response tool FIAT, developed out of NASA Ames, is currently being integrated into the TEMPEST environment. TPS recession, shape change, mass loss, and mass property alteration are all factors that can perturb an entry trajectory. For missions like Mars 2020, recession was minimal and was safely handled separately as a post process. For missions such as Jupiter Galileo with a high TPS mass fraction or asteroid entries, recession plays a major role. The proposed fully coupled scheme is to use an epoch-based approach where the trajectory integration is halted after a recession threshold, the energy balance and FIAT are solved at each panel, the mesh, aerodynamics, and mass properties are updated, and the trajectory continues. Several computational tradeoffs have been made during the development of TEMPEST to limit the cost of a single trajectory and preserve its utility as a conceptual, rapid iteration tool. Conclusion: Development of TEMPEST is ongoing and the project is still in its infancy. This talk aims to showcase its unique capabilities to support future NASA entry systems missions.

Bohdan O Wesely↗

Analysis of Mars 2020 Entry with Coupled Material Response and CFD

When computing the response of an ablating thermal protection system during entry, the aerothermal environment and material response are traditionally computed independently, with the introduction of a blowing correction term in the material response model to account for the outgassing of char and pyrolysis gases. This study presents an approach, where the pyrolysis blowing gases, calculated within the PATO material response code, are integrated into the DPLR hypersonic CFD code via a blowing boundary condition. This methodology employs an iterative process, whereby the blown pyrolysis gas products from PATO are incorporated into DPLR, refining surface heating predictions. The NEQAIR code is used to compute radiative heating. The method is applied in computing 3D material response of the Mars 2020 entry. When compared with uncoupled material response, the coupled simulations show a lower surface heat flux initially and a higher heat flux at peak heating as shown in Fig. 1. This is in agreement with previous work using a sphere case with environments from MSL.

Heat Transfer↗

Mars2020 Entry, Descent, and Landing Instrumentation 2 (MEDLI2) Do No Harm Test Series

A total of seventeen instrumented thermal sensor plugs, eight pressure transducers, two heat flux sensors, and one radiometer are planned to be utilized on the Mars 2020 missions thermal protection system (TPS) as part of the Mars Entry, Descent, and Landing Instrumentation II (MEDLI2) project. Of the MEDLI2 instrumentation, eleven instrumented thermal plugs and seven pressure transducers will be installed on the heatshield of the Mars 2020 vehicle while the rest will be installed on the backshell. The goal of the MEDLI2 instrumentation is to directly inform the large performance uncertainties that contribute to the design and validation of a Mars entry system. A better understanding of the entry environment and TPS performance could lead to reduced design margins enabling a greater payload mass-fraction and smaller landing ellipses. To prove that the MEDLI2 system will not degrade the performance of the Mars 2020 TPS, an Aerothermal Do No Harm (DNH) test series was designed and conducted. Like Mars 2020s predecessor, Mars Science Laboratory (MSL), the heatshield material will be Phenolic Impregnated Carbon Ablator (PICA); the Mars 2020 entry conditions are enveloped by the MSL design environments, therefore the development and qualification testing performed during MEDLI is sufficient to show that the similar MEDLI2 heatshield instrumentation will not degrade PICA performance. However, given that MEDLI did not include any backshell instrumentation, the MEDLI2 team was required to design and execute a DNH test series utilizing the backshell TPS material (SLA-561V) with the intended flight sensor suite. To meet the requirements handed down from Mars 2020, the MEDLI2 DNH test series emphasized the interaction between the MEDLI2 sensors and sensing locations with the surrounding backshell TPS and substrucutre. These interactions were characterized by performing environmental testing of four 12 by 12 test panels, which mimicked the construction of the backshell TPS and the integration of the MEDLI2 sensors as seen in Figure 1. The testing included thermal vacuumcycling, random vibration, shock, and arc jet testing. The test panels were fabricated by Lockheed Martin, establishing techniques that will be utilized during the Mars 2020 vehicle installation. Each test panel included one thermal sensor plug (two embedded thermocouples), one heat flux sensor, and multiple pressure port holes for evaluation.This presentation will discuss the planning and execution of the MEDLI2 DNH test series. Selected highlights and results of each environmental test will be presented, and lessons learned will be addressed that will feed forward into the planning for the MEDLI2 flight system certification testing.

backshell↗

Aerothermal modeling program

Some significant features of the approach adopted for the combustor aerothermal modeling program are described. The individual computerized models utilized in the aero design approach are characterized. The preliminary design module provides the overall envelope definition of the burner. The diffuser module provides the detailed contours of the diffuser and combustor cowl region, as well as the pressure loss characteristics into each of the individual flow passages into the dome and around the combustor. The flow distribution module provides the air entry quantities through each of the aperatures and the overall pressure drop. The heat transfer module provides detailed metal temperature distribution throughout the metal structure as input to stress and life analysis that are not part of the aerothermo design effort. Finally, the internal flow module, INTFLOW, is described and the approach for model evaluation using laboratory data is discussed.

Kenworthy, M.↗

Coupling CFD and Material Response for Analysis of Mars Entry

In computing the response of an ablating thermal protection system during atmospheric entry, the aerothermal environment and material response are generally computed separately with a blowing correction term in the material response model to account for the blowing of char and pyrolysis gases [1]. In this work, we apply a coupled approach in which pyrolysis blowing gases, computed in the PATO material response code [2], are used with a blowing boundary condition in the DPLR hypersonic CFD code [3]. This leads to an iterative method in which blowing products from PATO are input into DPLR to update surface heating estimates. The full iterative method, with the addition of radiative heating estimates using the NEQAIR radiation solver [4], is shown in Fig. 1. The method is demonstrated on a sphere case with the environment and material properties based on the Mars Science Laboratory entry. Future work includes utilizing this method in computing full 3D material response during the Mars 2020 entry.

Heat Transfer↗

Analysis of Mars 2020 Entry with Coupled Material Response and CFD

When computing the response of an ablating thermal protection system during entry, the aerothermal environment and material response are traditionally computed independently, with the introduction of a blowing correction term in the material response model to account for the outgassing of char and pyrolysis gases. This study presents an approach, where the pyrolysis blowing gases, calculated within the PATO material response code [1], are integrated into the DPLR hypersonic CFD code [2] via a blowing boundary condition. This methodology employs an iterative process, whereby the blown pyrolysis gas products from PATO are incorporated into DPLR, refining surface heating predictions. The NEQAIR code is used to compute radiative heating [3]. The method is applied in computing 3D material response of the Mars 2020 entry. When compared with uncoupled material response, the coupled simulations show a lower surface heat flux initially and a higher heat flux at peak heating as shown in Fig. 1. This is in agreement with previous work using a sphere case with environments from MSL [4].

Heat Transfer↗

Gas-jet and tangent-slot film cooling tests of a 12.5 deg cone at Mach number of 6.7

Tests were conducted in the Langley 8-Foot High Temperature Tunnel to determine the aerothermal effects of gaseous nitrogen-coolant ejection on a 3-ft base-diameter, 12.5 degree half-angle cone. Free-stream Mach number, total temperature, and unit Reynolds number per foot were 6.7, 3300 deg R, and 1.4 million, respectively. Two coolant ejection noses were tested, an ogive frustum with a forward-facing 0.8-in radius gas-jet tip, and a 3-in radius hemisphere with a 0.243-in high rearward-facing tangent slot. Data include surface pressures and heating rates, shock shapes, and shock-layer profiles; results are compared with no-cooling data obtained with 1-in and 3-in radius solid noses. Surface pressures were reduced with gas-jet ejection but were affected little by tangent-slot ejection. For both gas-jet and tangent-slot ejection, high coolant flow rates reduced heating even far downstream from the region of ejection; however, low coolant rates caused transition to turbulence and increased heating. Shock-layer profiles of pitot pressure, Mach number, and total temperature were reduced for both gas-jet and tangent-slot ejection. Insight into the gas-jet heat-flux mechanisms was obtained by using shock-layer rake data and established, no-cooling, heat-transfer equations.

Nowak, Robert J.↗

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.↗

Influence of nonequilibrium radiation and shape change on aerothermal environment of a Jovian entry body

The influence of nonequilibrium radiative energy transfer and the effect of probe configuration changes on the flow phenomena around a Jovian entry body are investigated. The radiating shock layer flow is assumed to be axisymmetric, viscous, laminar and in chemical equilibrium. The radiative transfer equations are derived under nonequilibrium conditions which include multilevel energy transitions. The equilibrium radiative transfer analysis is performed with an existing nongray radiation model which accounts for molecular band, atomic line, and continuum transitions. The nonequilibrium results are obtained with and without ablation injection in the shock layer. The nonequilibrium results are found to be greatly influenced by the temperature distribution in the shock layer. In the absence of ablative products, the convective and radiative heating to the entry body are reduced under nonequilibrium conditions. The influence of nonequilibrium is found to be greater at higher entry altitudes. With coupled ablation and carbon phenolic injection, 16 chemical species are used in the ablation layer for radiation absorption. Equilibrium and nonequilibrium results are compared under peak heating conditions.

Tiwari, S. N.↗

Numerical simulation of aerothermal loads in hypersonic engine inlets due to shock impingement

The effect of shock impingement on an axial corner simulating the inlet of a hypersonic vehicle engine is modeled using a finite-difference procedure. A three-dimensional dynamic grid adaptation procedure is utilized to move the grids to regions with strong flow gradients. The adaptation procedure uses a grid relocation stencil that is valid at both the interior and boundary points of the finite-difference grid. A linear combination of spatial derivatives of specific flow variables, calculated with finite-element interpolation functions, are used as adaptation measures. This computational procedure is used to study laminar and turbulent Mach 6 flows in the axial corner. The description of flow physics and qualitative measures of heat transfer distributions on cowl and strut surfaces obtained from the analysis are compared with experimental observations. Conclusions are drawn regarding the capability of the numerical scheme for enhanced modeling of high-speed compressible flows.

Ramakrishnan, R.↗

An evaluation of computer codes for simulating the Galileo Probe aerothermal entry environment

The approaches of three computer flow field codes (HYVIS, COLTS, and RASLE), used to determine the Galileo Probe aerothermal environment and its effect on the design of the thermal protection system, are analyzed in order to resolve differences in their predicted results. All three codes account for the hypersonic, massively blown, radiation shock layers, characteristic of Jupiter entry. Significant differences, however, are evident in their solution procedures: the governing conservation equations, the numerical differencing methods, the governing physics (chemical, radiation, diffusion, and turbulence models), and the basic physical data (thermodynamic, transport, chemical, and spectral properties for atomic and molecular species). Solutions are compared for two near peak heating entry conditions for a Galileo Probe baseline configuration, having an initial mass of 242 kg and simulating entry into the Orton nominal atmosphere. The modern numerical methodology of COLTS and RASLE appear to provide an improved capability for coupled flow-field solutions.

Menees, G. P.↗

Combustion hot section technology

The overall objective of the Turbine Engine Hot Section Technology Combustion Project is to develop and verify improved and more accurate analysis methods for increasing the ability to design with confidence the combustion system for advanced aircraft turbine engines. The analysis methods developed will be generically applicable to combustion systems and not restricted to one specific engine or manufacturer. This project's approach was to first assess and evaluate existing combustor aerothermal analysis models by means of a contracted effort initiated during FY 1982. This evaluation effort has assessed and quantified known models' strengths and deficiencies. During FY 1984 the Aerothermal Modeling Program, Phase 2 will be initiated, which is expected to have contracted model development efforts in the areas of improved numerical methods for turbulent viscous flows, flow interactions, and fuel spray flow foekd interactions. A Phase 3 effort is planned to address remaining model deficiencies. The primary inhouse effort in this area will be the determination of high pressure flame radiation characteristics in a full annular combustor. This experiment will be conducted in the NASA LeRC High Pressure Facility with the results compiled into a comprehensive flame radiation and liner heat flux model.

Ercegovic, D. B.↗

Development of a Tool to Recreate the Mars Science Laboratory Aerothermal Environment

The Mars Science Laboratory will enter the Martian atmosphere in 2012 with multiple char depth sensors and in-depth thermocouples in its heatshield. The aerothermal environment experienced by MSL may be computationally recreated using the data from the sensors and a material response program, such as the Fully Implicit Ablation and Thermal (FIAT) response program, through the matching of the char depth and thermocouple predictions of the material response program to the sensor data. A tool, CHanging Inputs from the Environment of FIAT (CHIEF), was developed to iteratively change different environmental conditions such that FIAT predictions match within certain criteria applied to an external data set. The computational environment is changed by iterating on the enthalpy, pressure, or heat transfer coefficient at certain times in the trajectory. CHIEF was initially compared against arc-jet test data from the development of the MSL heatshield and then against simulated sensor data derived from design trajectories for MSL. CHIEF was able to match char depth and in-depth thermocouple temperatures within the bounds placed upon it for these cases. Further refinement of CHIEF to compare multiple time points and assign convergence criteria may improve accuracy.

Beerman, A. F.↗