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NASA NTRS2016

Heatshield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASAs high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50 mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in its 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

Thermal Protection System↗

NASA NTRS1974

Thermal-Structural Evaluation of TD Ni-20Cr Thermal Protection System Panels

The results of a thermal-structural test program to verify the performance of a metallic/radiative Thermal Protection System (TPS) under reentry conditions are presented. This TPS panel is suitable for multiple reentry, high L/D space vehicles, such as the NASA space shuttle, having surface temperatures up to 1200 C (2200 F). The TPS panel tested consists of a corrugation-stiffened, beaded-skin TD Ni-20Cr metallic heat shield backed by a flexible fibrous quartz and radiative shield insulative system. Test conditions simulated the critical heating and aerodynamic pressure environments expected during 100 repeated missions of a reentry vehicle. Temperatures were measured during each reentry cycle; heat-shield flatness surveys to measure permanent set of the metallic components were made every 10 cycles. The TPS panel, in spite of localized surface failures, performed its designated function.

Eidinoff, H. L.↗

NASA NTRS2006

Apollo Seals: A Basis for the Crew Exploration Vehicle Seals

The National Aeronautics and Space Administration is currently designing the Crew Exploration Vehicle (CEV) as a replacement for the Space Shuttle for manned missions to the International Space Station, as a command module for returning astronauts to the moon, and as an earth reentry vehicle for the final leg of manned missions to the moon and Mars. The CEV resembles a scaled-up version of the heritage Apollo vehicle; however, the CEV seal requirements are different than those from Apollo because of its different mission requirements. A review is presented of some of the seals used on the Apollo spacecraft for the gap between the heat shield and backshell and for penetrations through the heat shield, docking hatches, windows, and the capsule pressure hull.

Finkbeiner, Joshua R.↗

NASA NTRS2007

Apollo Seals: A Basis for the Crew Exploration Vehicle Seals

Finkbeiner, Joshua R.↗

NASA NTRSDate not supplied

Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) Mission Overview, Science Return, and Future Applications of This Technology

The Low-Earth Orbit (LEO) Flight Test of an Inflatable Decelerator (LOFTID) mission was the culmination of two decades of research and development for Hyper-sonic Inflatable Aerodynamic Decelerator (HIAD) technology. LOFTID was a project overseen by the Technology Demonstration Mission (TDM) program within NASA’s Space Technology Mission Directorate. The success of the LOFTID mission could enable new NASA missions to Mars, Venus, and most solar-system destinations with atmospheres, as well as cost-effective payload returns to Earth, including in-space manufactured materials and launch vehicle asset recovery. LOFTID, with its unique inflatable heat shield, was the first-of-a-kind orbital reentry flight, and the largest blunt body atmospheric entry of any kind. On November 10, 2022, just over 10 years since the previous flight test of the smaller sub-orbital Inflatable Reentry Vehicle Experiment-3 (IRVE-3) [1], NASA Langley Research Center, with partner United Launch Alliance (ULA), successfully launched and achieved reentry and recovery of the LOFTID Reentry Vehicle (RV), further demonstrating the viability of the HIAD technology for large-diameter, inflatable heat shields to safely and accurately deliver large payloads through an atmosphere via a controlled descent and landing. Launching as a secondary payload with the Joint Polar Satellite System 2 (JPSS-2) from Vandenberg Space Force Base, California, stowed inside an ex-tended payload adapter of the Atlas V 401 launch vehicle, the LOFTID mission officially began after the JPSS-2 payload was delivered to its orbit by the Centaur second stage. The LOFTID RV was flying solo on its spin-stabilized ballistic reentry trajectory about one hour after launch, and the flight ended approximately one hour later with a gentle splashdown under parachute in the Pacific Ocean off the east coast of Hawaii, where the RV was recovered and later shipped back to NASA Langley. LOFTID endured the harsh environments of atmospheric reentry while demonstrating stable aerodynamics through the entire spectrum of hypersonic, supersonic, transonic, and subsonic flight. The LOFTID RV was exposed to an aeroheating environment representative of many Mars and LEO HIAD applications, while successfully demonstrating the ability of the heat-affected inflatable structure to with-stand aerodynamic forces that exceeded those expected at Mars. This flight demonstration of a 6m diameter HIAD confirmed the technology structural and thermal performance as it protected the 1100kg RV entering Earth’s atmosphere at 8 km/s, reaching Mach 30, and experiencing 9g deceleration before deploying parachutes and splashing down in the Pacific Ocean. HIAD technology involves an aeroshell that can be hard packed into a small volume for launch and then deployed prior to atmospheric entry for a controlled deceleration through the atmosphere. Large deployable heat shields enable spacecraft to carry bigger, heavier payloads, including scientific instruments and human support systems for planetary landing and exploration. Much larger than traditional fixed diameter aeroshells that are constrained by the size of launch vehicle shrouds, inflatable decelerators create more drag and start the deceleration process in the upper reaches of the atmosphere with greater efficiency and stability. LOFTID’s successful demonstration of the HIAD technology has greatly expanded NASA’s options for future planetary missions and opened new commercial opportunities for lower-cost mission pay-load recovery including recovery of launch vehicle assets, or as a delivery system to return cargo from the International Space Station or cislunar space. The developments for some of these applications are al-ready underway. While LOFTID was indeed a first-of-a-kind flight for an inflatable heatshield, the largest blunt-body entry ever, its remarkable performance assured that it will not be the last of its kind.

John DiNonno↗

NASA NTRS1981

Survey of the supporting research and technology for the thermal protection of the Galileo Probe

The Galileo Probe, which is scheduled to be launched in 1985 and to enter the hydrogen-helium atmosphere of Jupiter up to 1,475 days later, presents thermal protection problems that are far more difficult than those experienced in previous planetary entry missions. The high entry speed of the Probe will cause forebody heating rates orders of magnitude greater than those encountered in the Apollo and Pioneer Venus missions, severe afterbody heating from base-flow radiation, and thermochemical ablation rates for carbon phenolic that rival the free-stream mass flux. This paper presents a comprehensive survey of the experimental work and computational research that provide technological support for the Probe's heat-shield design effort. The survey includes atmospheric modeling; both approximate and first-principle computations of flow fields and heat-shield material response; base heating; turbulence modelling; new computational techniques; experimental heating and materials studies; code validation efforts; and a set of 'consensus' first-principle flow-field solutions through the entry maneuver, with predictions of the corresponding thermal protection requirements.

Howe, J. T.↗

NASA NTRS2013

Folding Elastic Thermal Surface - FETS

The FETS is a light and compact thermal surface (sun shade, IR thermal shield, cover, and/or deployable radiator) that is mounted on a set of offset tape-spring hinges. The thermal surface is constrained during launch and activated in space by a thermomechanical latch such as a wax actuator. An application-specific embodiment of this technology developed for the MATMOS (Mars Atmospheric Trace Molecule Occultation Spectrometer) project serves as a deployable cover and thermal shield for its passive cooler. The FETS fits compactly against the instrument within the constrained launch envelope, and then unfolds into a larger area once in space. In this application, the FETS protects the passive cooler from thermal damage and contamination during ground operations, launch, and during orbit insertion. Once unfolded or deployed, the FETS serves as a heat shield, intercepting parasitic heat loads by blocking the passive cooler s view of the warm spacecraft. The technology significantly enhances the capabilities of instruments requiring either active or passive cooling of optical detectors. This can be particularly important for instruments where performance is limited by the available radiator area. Examples would be IR optical instruments on CubeSATs or those launched as hosted payloads because radiator area is limited and views are often undesirable. As a deployable radiator, the panels making up the FETS are linked thermally by thermal straps and heat pipes; the structural support and deployment energy is provided using tape-spring hinges. The FETS is a novel combination of existing technologies. Prior art for deployable heat shields uses rotating hinges that typically must be lubricated to avoid cold welding or static friction. By using tape-spring hinges, the FETS avoids the need for lubricants by avoiding friction altogether. This also eliminates the potential for contamination of nearby cooled optics by outgassing lubricants. Furthermore, the tape-spring design of the FETS is also self-locking so the panels stay in a rigid and extended configuration after deployment. This unexpected benefit makes the tape-spring hinge design of the FETS a light, simple, reliable, compact, non-outgassing hinge, spring, and latch. While tape-spring hinges are not novel, they have never been used to deploy passive unfolding thermal surfaces (radiator panels, covers, sun shades, or IR thermal shields). Furthermore, because this technology is compact, it has minimal impact on the launch envelope and mass specifications. FETS enhances the performance of hosted payload instruments where the science data is limited by dark noise. Incorporating FETS into a thermal control system increases radiator area, which lowers the optical detector temperature. This results in higher SNR (signal-to-noise ratio) and improved science data.

Urquiza, Eugenio↗

NASA NTRS2002

Control Surface and Afterbody Experimental Aeroheating for a Proposed Mars Smart Lander Aeroshell

Several configurations, having a Viking aeroshell heritage and providing lift-to-drag required for precision landing, have been considered for a proposed Mars Smart Lander. An experimental aeroheating investigation of two configurations, one having a blended tab and the other a blended shelf control surface, has been conducted at the NASA Langley Research Center in the 20-Inch Mach 6 Air Tunnel to assess heating levels on these control surfaces and their effects on afterbody heating. The proposed Mars Smart Lander concept is to be attached through its aeroshell to the main spacecraft bus, thereby producing cavities in the forebody heat shield upon separation prior to entry into the Martian atmosphere. The effects these cavities will have on the heating levels experienced by the control surface and the afterbody were also examined. The effects of Reynolds number, angle-of-attack, and cavity location on aeroheating levels and distributions were determined and are presented. At the highest angle-of-attack, blended tab heating was increased due to transitional reattachment of the separated shear layer. The placement of cavities downstream of the control surface greatly influenced aeroheating levels and distributions. Forebody heat shield cavities had no effect on afterbody heating and the presence of control surfaces decreased leeward afterbody heating slightly.

Liechty, Derek S.↗

NASA NTRS1964

Dynamic Model Investigation of the Landing Characteristics of a Manned Spacecraft

Investigations were made to study the water-landing and certain grounds-surface landing characteristics of a Gemini spacecraft model. The water landing experiments were made by simulating paraglider and parachute letdowns with two 1/6- scale model configurations. Parameters included various combinations of attitude, horizontal speed, vertical speed, and landing skids extended and retracted. Investigations were made in calm water and in waves. The paraglider landings at horizontal speeds of 63 feet per second (19.8 m/sec) which resulted in a noseover or tumbling shortly after initial water contact. The maximum longitudinal acceleration of the model in calm water was about 14g units, and the maximum angular acceleration was 66 radians per second squared. In the parachute landings with the heat shield forward, the model skidded along the water surface on the heat shield. Parachute landings with the small end forward resulted in behavior similar to that of the paraglider landings. The ground-surface landings were made with a 1/3-scale model by simulating a parachute letdown with braking rockets, which were fired prior to touchdown to dissipate vertical velocity. In these landings, control of timing and aligning the rockets on the model was very critical, and violent behavior resulted when either rocket alignment or timing was in error. In the landings that were correctly controlled, the model either remained upright or slowly rolled over on its side.

EXPERIMENTS↗

NASA NTRS1963

Landing Characteristics of a Re-entry Vehicle with a Passive Landing System for Impact Alleviation

An experimental investigation was made to determine the landing characteristics of a 1/8-scale dynamic model of a reentry vehicle using a passive landing system to alleviate the landing-impact loads. The passive landing system consisted of a flexible heat shield with a small section of aluminum honeycomb placed between the heat shield and the crew compartment at the point that would be the first to contact the landing surface. The model was landed on concrete and sand landing surfaces at parachute letdown velocities. The investigations simulated a vertical velocity of 30 ft/sec (full scale), horizontal velocities of 0, 15, 30, 40, and 50 ft/sec (full scale), and landing attitudes ranging from -30 degrees to 20 degrees. The model investigation indicated that stable landings could be made on a concrete surface at horizontal velocities up to about 30 ft/sec, but the stable landing-attitude range at these speeds was small. The aluminum honeycomb bottomed occasionally during landings on concrete. When bottoming did not occur, maximum normal and longitudinal accelerations at the center of gravity of the vehicle were approximately 50g and 30g, respectively.

Stubbs, Sandy M.↗

NASA NTRS2012

Attitude determination with three-axis accelerometer for emergency atmospheric entry

Two algorithms are disclosed that, with the use of a 3-axis accelerometer, will be able to determine the angles of attack, sideslip and roll of a capsule-type spacecraft prior to entry (at very high altitudes, where the atmospheric density is still very low) and during entry. The invention relates to emergency situations in which no reliable attitude and attitude rate are available. Provided that the spacecraft would not attempt a guided entry without reliable attitude information, the objective of the entry system in such case would be to attempt a safe ballistic entry. A ballistic entry requires three controlled phases to be executed in sequence: First, cancel initial rates in case the spacecraft is tumbling; second, maneuver the capsule to a heat-shield-forward attitude, preferably to the trim attitude, to counteract the heat rate and heat load build up; and third, impart a ballistic bank or roll rate to null the average lift vector in order to prevent prolonged lift down situations. Being able to know the attitude, hence the attitude rate, will allow the control system (nominal or backup, automatic or manual) to cancel any initial angular rates. Also, since a heat-shield forward attitude and the trim attitude can be specified in terms of the angles of attack and sideslip, being able to determine the current attitude in terms of these angles will allow the control system to maneuver the vehicle to the desired attitude. Finally, being able to determine the roll angle will allow for the control of the roll ballistic rate during entry.

Garcia-Llama, Eduardo↗

NASA NTRS1982

Comparison of evolving photovoltaic and nuclear power systems for earth orbital applications

Photovoltaic and fission reactor orbital power systems are compared in terms of the end-to-end system power-to-mass ratios. Three PV systems are examined, i.e., a solid substrate with a cell array and a NiCd battery, a modified SEP array and an NiH2 battery, and a 62-micron Si cell array and a fuel cell. All arrays were modeled to be 13.5% efficient and to produce 25 kW dc. The SP-100 reactor consists of the heat source, radiation shield, heat pipes to transfer thermal energy from the reactor to thermoelectric elements, and a waste heat radiator. Consideration is given to system applications in orbits ranging from LEO to GEO, and to mission durations of 1, 5, and 10 yr. PV systems are concluded to be flight-proven, useful out of radiation belts, and best for low to moderate power levels. Limitations exist for operations where atmospheric drag may become a factor and due to the size of a large PV power supply. Space nuclear reactors will continue under development and uses at high power levels and in low altitude orbits are foreseen.

Rockey, D. E.↗

NASA NTRS2011

Flexible Ablators: Applications and Arcjet Testing

Flexible ablators were conceived in 2009 to meet the technology pull for large, human Mars Exploration Class, 23 m diameter hypersonic inflatable aerodynamic decelerators. As described elsewhere, they have been recently undergoing initial technical readiness (TRL) advancement by NASA. The performance limits of flexible ablators in terms of maximum heat rates, pressure and shear remain to be defined. Further, it is hoped that this emerging technology will vastly expand the capability of future NASA missions involving atmospheric entry systems. This paper considers four topics of relevance to flexible ablators: (1) Their potential applications to near/far term human and robotic missions (2) Brief consideration of the balance between heat shield diameter, flexible ablator performance limits, entry vehicle controllability and aft-body shear layer impingement of interest to designers of very large entry vehicles, (3) The approach for developing bonding processes of flexible ablators for use on rigid entry bodies and (4) Design of large arcjet test articles that will enable the testing of flexible ablators in flight-like, combined environments (heat flux, pressure, shear and structural tensile loading). Based on a review of thermal protection system performance requirements for future entry vehicles, it is concluded that flexible ablators have broad applications to conventional, rigid entry body systems and are enabling to large deployable (both inflatable and mechanical) heat shields. Because of the game-changing nature of flexible ablators, it appears that NASA's Office of the Chief Technologist (OCT) will fund a focused, 3-year TRL advancement of the new materials capable of performance in heat fluxes in the range of 200-600 W/sq. cm. This support will enable the manufacture and use of the large-scale arcjet test designs that will be a key element of this OCT funded activity.

Thermal Protection↗

NASA NTRS1979

Several preliminary designs for heavy-lift earth-to-orbit transport

Several design concepts are identified for earth-to-orbit delivery of payloads in the 200 Mg range. The concept include winged vehicles which take-off vertically and land horizontally and ballistic shapes similar to the Gemini or Mercury vehicles which take-off and land vertically. Major technology issues include stability problems for the winged vehicle with large base mounted engines and heat shield design problems for the ballistic vehicle, the latter requiring doors in the heat shield for the main engines.

Brien, E. P.↗

NASA NTRS1994

Trajectory-based heating analysis for the European Space Agency/Rosetta Earth Return Vehicle

A coupled, trajectory-based flowfield and material thermal-response analysis is presented for the European Space Agency proposed Rosetta comet nucleus sample return vehicle. The probe returns to earth along a hyperbolic trajectory with an entry velocity of 16.5 km/s and requires an ablative heat shield on the forebody. Combined radiative and convective ablating flowfield analyses were performed for the significant heating portion of the shallow ballistic entry trajectory. Both quasisteady ablation and fully transient analyses were performed for a heat shield composed of carbon-phenolic ablative material. Quasisteady analysis was performed using the two-dimensional axisymmetric codes RASLE and BLIMPK. Transient computational results were obtained from the one-dimensional ablation/conduction code CMA. Results are presented for heating, temperature, and ablation rate distributions over the probe forebody for various trajectory points. Comparison of transient and quasisteady results indicates that, for the heating pulse encountered by this probe, the quasisteady approach is conservative from the standpoint of predicted surface recession.

RADIATIVE ABLATING FLOWFIELD A↗

NASA NTRS1993

Trajectory-based heating analysis for the ESA/Rosetta earth return vehicle

A coupled, trajectory based flowfield and material thermal response analysis is presented for the European Space Agency (ESA) proposed Rosetta comet nucleus sample return vehicle. The probe returns to Earth along a hyperbolic trajectory with an entry velocity of 16.5 km/sec and requires an ablative heat shield on the forebody. Combined radiative and convective, ablating flowfield analyses were performed for the significant heating portion of the shallow ballistic entry trajectory. Both quasi-steady ablation and fully transient analyses were performed for a heat shield composed of carbon-phenolic ablative material. Quasi-steady analysis was performed using the two-dimensional, axisymmetric codes RASLE and BLIMPK. Transient computational results were obtained from the one-dimensional ablation/conduction code, CMA. Results are presented for heating, temperature and ablation rate distributions over the probe forebody for various trajectory points. Comparison of transient and quasi-steady results indicates that, for the heating pulse encountered by this probe, the quasi-static approach is conservative from the standpoint of predicted surface recession.

Henline, William D.↗

NASA NTRS1996

Design and Laboratory Validation of a Capacitive Sensor for Measuring the Recession of Thin-Layered Ablator

Flight vehicles are typically instrumented with subsurface thermocouples to estimate heat transfer at the surface using inverse analysis procedures. If the vehicle has an ablating heat shield, however, temperature time histories from subsurface thermocouples no longer provide enough information to estimate heat flux at the surface. In this situation, the geometry changes and thermal energy leaves the surface in the form of ablation products. The ablation rate is required to estimate heat transfer to the surface. A new concept for a capacitive sensor has been developed to measure ablator depth using the ablator's dielectric effect on a capacitor's fringe region. Relying on the capacitor's fringe region enables the gage to be flush mounted in the vehicle's permanent structure and not intrude into the ablative heat shield applied over the gage. This sensor's design allows nonintrusive measurement of the thickness of dielectric materials, in particular, the recession rates of low-temperature ablators applied in thin (0.020 to 0.060 in. (0.05 to 0.15 mm)) layers. Twenty capacitive gages with 13 different sensing element geometries were designed, fabricated, and tested. A two-dimensional finite-element analysis was performed on several candidate geometries. Calibration procedures using ablator-simulating shims are described. A one-to-one correspondence between system output and dielectric material thickness was observed out to a thickness of 0.055 in. (1.4 mm) for a material with a permittivity about three times that of air or vacuum. A novel method of monitoring the change in sensor capacitance was developed. This technical memorandum suggests further improvements in gage design and fabrication techniques.

Gregory K Noffz↗

NASA NTRS1997

JAE: A Jupiter Atmospheric Entry Probe Heating Code

The strong gravitational attraction of Jupiter on probes approaching the planet results in very high atmospheric entry velocities. The values relative to the rotating atmosphere can vary from about 47 to 60 km/sec, depending on the latitude of the entry. Therefore, the peak heating rates and heat shield mass fractions exceed those for any other atmospheric entries. For example, the Galileo probe's heat shield mass fraction was 50%, of which 45% was devoted to the forebody. Although the Galileo probe's mission was very successful, many more scientific questions about the Jovian atmosphere remain to be answered and additional probe missions are being planned. Recent developments in microelectronics have raised the possibility of building smaller and less expensive probes than Galileo. Therefore, it was desirable to develop a code that could quickly compute the forebody entry heating environments when performing parametric probe sizing studies. The Jupiter Atmospheric Entry (JAE) code was developed to meet this requirement. The body geometry consists of a blunt-nosed conical shape of arbitrary nose and base radius and cone angles up to about 65 deg at zero angle of attack.

Wercinski, Paul F.↗