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

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At least 379 records · Page 21

Entry into outer planet environments. I - The radiating shock layer with coupled ablation for carbon and silica

Fully coupled solutions of shock layer equations for the stagnation region are obtained, comprising a set of converged benchmark flowfield solutions for silica and carbon heat shields entering modeled atmospheres of Saturn and Uranus. Model atmospheres and entry trajectories providing significant radiative heating to the entry probes so that the heating environment and effects of mass addition on the heating environment are clearly defined are emphasized. Results referable to the carbon heat shield are questioned because of the high (sublimation) wall temperature assumed and the relatively low shock layer temperature.

Liu, C.-H.↗

Dynamic Model Investigation of Water Pressures and Accelerations Encountered During Landings of the Apollo Spacecraft

An experimental investigation was made to determine impact water pressures, accelerations, and landing dynamics of a 1/4-scale dynamic model of the command module of the Apollo spacecraft. A scaled-stiffness aft heat shield was used on the model to simulate the structural deflections of the full-scale heat shield. Tests were made on water to obtain impact pressure data at a simulated parachute letdown (vertical) velocity component of approximately 30 ft/sec (9.1 m/sec) full scale. Additional tests were made on water, sand, and hard clay-gravel landing surfaces at simulated vertical velocity components of 23 ft/sec (7.0 m/sec) full scale. Horizontal velocity components investigated ranged from 0 to 50 ft/sec (15 m/sec) full scale and the pitch attitudes ranged from -40 degrees to 29 degrees. Roll attitudes were O degrees, 90 degrees, and 180 degrees, and the yaw attitude was 0 degrees.

Tests↗

Woven TPS - A New Approach to TPS Design and Manufacturing

NASA's Office of the Chief Technologist (OCT) Game Changing Division recently funded an effort to advance a Woven TPS (WTPS) concept. WTPS is a new approach to producing TPS materials that uses precisely engineered 3D weaving techniques to customize material characteristics needed to meet specific missions requirements for protecting space vehicles from the intense heating generated during atmospheric entry. Using WTPS, sustainable, scalable, mission-optimized TPS solutions can be achieved with relatively low life cycle costs compared with the high costs and long development schedules currently associated with material development and certification. WTPS leverages the mature state-of-the-art weaving technology that has evolved from the textile industry to design TPS materials with tailorable performance by varying material composition and properties via the controlled placement of fibers within a woven structure. The resulting material can be designed to perform optimally for a wide range of entry conditions encompassing NASAs current and future mission needs. WTPS enables these optimized TPS designs to be translated precisely into mission-specific, manufactured materials that can substantially increase the efficiency, utility, and robustness of heat shield materials compared to the current state-of-the-art material options. By delivering improved heat shield performance and affordability, this technology will impact all future exploration missions, from the robotic in-situ science missions to Mars, Venus and Saturn to the next generation of human missions. WTPS can change the way NASA develops, certifies, and integrates TPS into mission life cycles - instead of being a mission constraint, TPS will become a mission enabler. It is anticipated that WTPS will have direct impact on SMD, HEOMD and OCT and will be of interest for DoD and COTS applications. This presentation will overview the WTPS concept and present some results from initial testing completed.

Feldman, Jay↗

TPSAS-NF1676L-21180-DND

Ablative materials are used as the Thermal Protection System (TPS) for space vehicles that enter a planetary atmosphere. During the entry phase, the vehicle experiences high rates of aerodynamic heating. These ablative materials, acting as a heat shield, protect the vehicle from the harsh environment and ensure a safe entry. Ablative materials reduce the incoming heat flux through various phenomena such as near-surface oxidation, pyrolysis chemical reaction, vaporization, and other erosive processes, collectively known as ablation. Spallation is one such ablative process, in which solid particles are ejected from the material into the flow field. The many conditions leading to spallation, however, are not well understood and cannot be described accurately by simple phenomenological models. However, the spallation phenomenon might impact the aerodynamic heating rates of re-entry vehicles using ablative heat shields. For example, the solid particles ejected from the surface can modify the near surface chemical processes and flow field. To investigate spallation effects, a code was developed to compute the dynamics of spalled particles. The code uses a finite-rate chemistry model to study the chemical interactions of the particles with the flow field. The spallation code is dynamically coupled to a CFD solver that models the time accurate hypersonic flow field around an ablative sample. An experimental investigation was also performed at the NASA Langley HYMETS facility. HYMETS is a 400 kW arcjet that can simulate hypersonic flight and Earth or Martian entry conditions. Using high speed cameras, an IR camera, NIR and UV-VIS spectrometers, and other diagnostic instruments, test data on various graphite, LI-900, FiberForm, and PICA test samples were obtained, using target heat flux conditions of 100, 200, and 400 W/cm 2 . From the test campaign, measurements of particle velocity, acceleration and trajectory are obtained.

A Martin↗

High Enthalpy Studies of Capsule Heating in an Expansion Tunnel Facility

Measurements were made on an Orion heat shield model to demonstrate the capability of the new LENS-XX expansion tunnel facility to make high quality measurements of heat transfer distributions at flow velocities from 3 km/s (h(sub 0) = 5 MJ/kg) to 8.4 km/s (h(sub 0) = 36 MJ/kg). Thirty-nine heat transfer gauges, including both thin-film and thermocouple instruments, as well as four pressure gauges, and high-speed Schlieren were used to assess the aerothermal environment on the capsule heat shield. Only results from laminar boundary layer runs are reported. A major finding of this test series is that the high enthalpy, low-density flows displayed surface heating behavior that is observed to be consistent with some finite-rate recombination process occurring on the surface of the model. It is too early to speculate on the nature of the mechanism, but the response of the gages on the surface seems generally repeatable and consistent for a range of conditions. This result is an important milestone in developing and proving a capability to make measurements in a ground test environment and extrapolate them to flight for conditions with extreme non-equilibrium effects. Additionally, no significant, isolated stagnation point augmentation ("bump") was observed in the tests in this facility. Cases at higher Reynolds number seemed to show the greatest amount of overall increase in heating on the windward side of the model, which may in part be due to small-scale particulate.

Dufrene, Aaron↗

Effects of roughness on heating and boundary-layer transition. Part 1: Effects of simulated panel joints on boundary-layer transition

The effects of distributed roughness, arising from space shuttle orbiter panel joints, on boundary layer transition are investigated. The North American Rockwell 134B delta wing shuttle configuration was used for the study. Results show: (1) Premature boundary layer transition occurred in models having simulated heat shield panels with rased joints. (2) Laminar flow was maintained with slot type panel joint models to a Reynolds number twice that at which transition occurred in raised joints. (3) Significant increases in peak surface temperature and the time during which turbulent flow occurs may result from distributed roughness of heat shield panel joints. (4) Laminar and turbulent heating levels were predicted within available theories. (5) A complex interference between the wing and fuselage flow was observed in the delta wing model.

Seegmiller, H. L.↗

Thermal Protection System P50 Cork Environments and Response due to Radiative Heating

Space Launch System (SLS) experienced deflagration of the acreage of the Core Stage base heat shield during the Green Run hot-fire test campaigns and Artemis I flight. The burning products from the base heat shield during Green Run hot-fire test operation led to concerns in aerothermal environments and thermal protection system (TPS) performance prior to Artemis I flight. This work documents a highly controlled ground test within the NASA Marshall Space Flight Center’s Nonmetallic Materials Branch thermal vacuum chamber (TVC) and investigates the P50 cork heat transfer environments and thermal protection system (TPS) response due to sensitivity changes in radiative heat rates, ambient pressure, air entrainment mass flow rates, test gas and TPS sample types. An SLS ascent ambient pressure profile was also simulated within the TVC facility. This test data enabled the efforts toward the Artemis I SLS post-flight reconstruction and initial assessment of flight TPS performance. A ground test program was developed to gain an in-depth understanding of the cork combustion dynamics and TPS response due to the SLS launch vehicle flight ascent environments.

thermal protection system↗

Testing Lunar Return Thermal Protection Systems using Sub-Scale Flight Test Vehicles

A key objective of NASA's Vision for Space Exploration is to revisit the lunar surface. Such an ambitious goal requires the development of a new human-rated spacecraft, the Orion Crew Exploration Vehicle (CEV), to ferry crews to low earth orbit and to the moon. The successful conclusion of both types of missions will require a thermal protection system (TPS) capable of protecting the vehicle and crew from the extreme heat of atmospheric reentry. As a part of the TPS development, various materials are being tested in arcjet tunnels; however, the combined lunar return aerothermal environment of high heat flux, shear stress, and surface pressure cannot be duplicated using only existing ground test facilities. To ensure full TPS qualification, a flight test program using sub-scale Orion capsules has been proposed to test TPS materials and heat shield construction techniques under the most stressing combination of lunar return aerothermal environments. Originally called Testing Of Reentry Capsule Heat Shield, or TORCH, but later renamed LEX, for Lunar Reentry Experiment, the proposed flight test program is presented along with the driving requirements and descriptions of the vehicle and the TPS instrumentation suite slated to conduct in-flight measurements.

heatshield↗

Bringing the Heat: Thermal Protection Systems for Low Earth Orbit Transportation and Lunar Exploration

Thermal protection systems (TPS) protect spacecraft from the heating associated with hypersonic flight through a planet’s atmosphere. The materials are subjected to extreme heating and the overall system must be engineered to reliably protect the spacecraft structure during atmospheric entry. The talk will introduce TPS and describe three NASA-led efforts to develop TPS materials and manufacturing processes. The first effort studied thermally stable ceramic aerogels for use in thermal barriers and high temperature seals. A design framework for such materials is proposed, linking the thermal stability performance data with existing material property measurements. The second project, Additive Manufacturing of Thermal Protection Systems (AMTPS), developed an automated, additive approach for ablative heat shield manufacturing. Novel material systems and manufacturing methods were developed to reduce the time required to manufacture ablative TPS heat shields. The third effort tackles a critical challenge of material obsolescence for silica fiber based reusable TPS. The properties and performance of heritage silica fiber are quantified and compared to modern alternatives to support qualification for flight. The talk will also describe other work in TPS conducted by the Thermal Design Branch at NASA JSC and opportunities for students and faculty to get involved with NASA.

Nathaniel Olson↗

Carbon Nanotube-Enhanced Carbon-Phenenolic Ablator Material

This viewgraph presentation reviews the use of PICA (phenolic impregnated carbon ablator) as the selected material for heat shielding for future earth return vehicles. It briefly reviews the manufacturing of PICA and the advantages for the use of heat shielding, and then explains the reason for using Carbon Nanotubes to improve strength of phenolic resin that binds carbon fibers together. It reviews the work being done to create a carbon nanotube enhanced PICA. Also shown are various micrographic images of the various PICA materials.

Kikolaev, P.↗

Reentry Thermal Analysis of a Generic Crew Exploration Vehicle Structure

Comparative studies were performed on the heat-shielding characteristics of honeycomb-core sandwich panels fabricated with different materials for possible use as wall panels for the proposed crew exploration vehicle. Graphite/epoxy sandwich panel was found to outperform aluminum sandwich panel under the same geometry due to superior heat-shielding qualities and lower material density. Also, representative reentry heat-transfer analysis was performed on the windward wall structures of a generic crew exploration vehicle. The Apollo low Earth orbit reentry trajectory was used to calculate the reentry heating rates. The generic crew exploration vehicle has a graphite/epoxy composite honeycomb sandwich exterior wall and an aluminum honeycomb sandwich interior wall, and is protected with the Apollo thermal protection system ablative material. In the thermal analysis computer program used, the TPS ablation effect was not yet included; however, the results from the nonablation heat-transfer analyses were used to develop a "virtual ablation" method to estimate the ablation heat loads and the thermal protection system recession thicknesses. Depending on the severity of the heating-rate time history, the virtual ablation period was found to last for 87 to 107 seconds and the ablation heat load was estimated to be in the range of 86 to 88 percent of the total heat load for the ablation time period. The thermal protection system recession thickness was estimated to be in the range of 0.08 to 0.11 inches. For the crew exploration vehicle zero-tilt and 18-degree-tilt stagnation points, thermal protection system thicknesses of h = {0.717, 0.733} inches were found to be adequate to keep the substructural composite sandwich temperature below the limit of 300 F.

Ko, William L.↗

Aerothermodynamic environment and thermal protection for a Titan aerocapture vehicle

This paper presents thermal protection system (TPS) requirements for a potential Titan aerocapture vehicle. Shock-layer solutions are obtained for a nominal trajectory through the current Titan model atmosphere. Fully laminar and fully turbulent solutions are presented along the blunted fore-cone in the windward symmetry plane of a bent-biconic vehicle. Using these solutions to define the aerothermodynamic environment, transient material-response solutions are obtained for a Galileo-type TPS with a carbon-phenolic ablator heat shield. Shock-layer results indicate that turbulent flow is the more realistic flow condition. They also show that the lengthy aerocapture heating pulse is dominated by convective heating. The TPS results show that the required insulation thickness is uniformly about 4 cm along the fore-cone because of the long heat-soak period. The total heat-shield thickness is 6.4 cm at the stagnation point, and 4.7 cm near the end of the fore-cone. These TPS requirements are greater than those presented in a previous Titan aerocapture study.

Green, M. J.↗

Aerothermodynamic Environment Definition for the Genesis Sample Return Capsule

NASA's Genesis sample return mission will be the first to return material from beyond the Earth-Moon system. NASA Langley Research Center supported this mission with aerothermodynamic analyses of the sample return capsule. This paper provides an overview of that effort. The capsule is attached through its forebody to the spacecraft bus. When the attachment is severed prior to Earth entry, forebody cavities remain. The presence of these cavities could dramatically increase the heating environment in their vicinity and downstream. A combination of computational fluid dynamics calculations and wind tunnel phosphor thermography tests were employed to address this issue. These results quantify the heating environment in and around the cavities, and were a factor in the decision to switch forebody heat shield materials. A transition map is developed which predicts that the flow aft of the penetrations will still be laminar at the peak heating point of the trajectory. As the vehicle continues along the trajectory to the peak dynamic pressure point, fully turbulent flow aft of the penetrations could occur. The integrated heat load calculations show that a heat shield sized to the stagnation point levels will be adequate for the predicted environment aft of the penetrations.

Cheatwood, F. McNeil↗

Fire-Resistant Reinforcement Makes Steel Structures Sturdier

Built and designed by Avco Corporation, the Apollo heat shield was coated with an ablative material whose purpose was to burn and, thus, dissipate energy. The material charred to form a protective coating which blocked heat penetration beyond the outer surface. Avco Corporation subsequently entered into a contract with Ames Research Center to develop spinoff applications of the heat shield in the arena of fire protection, specifically for the development of fire-retardant paints and foams for aircraft. This experience led to the production of Chartek 59, manufactured by Avco Specialty Materials (a subsidiary of Avco Corporation eventually acquired by Textron, Inc.) and marketed as the world s first intumescent epoxy material. As an intumescent coating, Chartek 59 expanded in volume when exposed to heat or flames and acted as an insulating barrier. It also retained its space-age ablative properties and dissipated heat through burn-off. Further applications were discovered, and the fireproofing formulation found its way into oil refineries, chemical plants, and other industrial facilities working with highly flammable products.

Source record↗

Aerothermal Effects of Cavities and Protuberances for High-Speed Sample Return Capsules

Extraterrestrial sample return is a growing component of solar system exploration. Currently, four missions, Stardust, 1 Muses-C, 2 Genesis, and Mars Sample Return, are under development that employ sample return as a prime component of the mission architecture. Respectively, these missions will return samples from the tail of a comet, an asteroid, the solar wind, and, Mars. An important component of these missions and the focus of this paper is the design of the sample return capsule (SRC). The purpose of the SRC is to safely return to Earth any gathered samples for terrestrial analysis. The two major design constraints for any SRC are as follows: 1) it must be able to survive a high-speed Earth entry (11 km/s to as a high as 15 km/s), 2) the mass of the SRC must be as small as possible. Because the SRC mass is carried from Earth to the sample sight and back, the SRC mass is a strong driver in the mission mass budget. Further, for the Mars Sample Return Capsule, planetary protection is another constraint. For this capsule, the probability of planetary contamination at Earth due to an SRC failure at entry must be minimal. For an SRC, a possible failure mechanism is severe local heating as a result of cavities and or protuberances in the SRC forebody heatshield. For example, the Apollo Command Module had a number of cavities and protuberances as part of the baseline designs Wind-tunnel tests of models containing small cavities and protuberances showed severe local heating augmentations in the vicinity of these surface discontinuities.4-5 As another example, the Genesis SRC forebody heat-shield contains penetrations (cavities) to mount the vehicle to the carrier bus. It is expected that these penetrations will also experience a severe local heating environment. A concern is that the large thermal gradients may produce sufficient thermal stress to cause local mechanical failure of the heatshield. Penetrations to the forebody heat-shield can also result from damage at vehicle integration, during launch, or during transportation of the sample return capsule from earth to the sample site and back. For example, the Starting SRC was damaged near the shoulder during the heatshield integration process producing a local surface discontinuity. Also, the Starting SRC traverses through the tail of a comet and is in space for 7 years. Thus, damage to the heatshield as a result of micrometeroid impact is a concern. Finally, it is difficult to characterize the effects of these potential heatshield singularities with ground-test facilities. Either detailed simulation or a dedicated flight test is required.

Olynick, David↗

Probabilistic Risk Analysis and Margin Process for a Flexible Thermal Protection System

Atmospheric entry vehicle thermal protection systems are margined due to the uncertainties that exist in entry aeroheating environments and the thermal response of the materials and structures. Entry vehicle thermal protections systems are traditionally over-margined for the heat loads that are experienced along the entry trajectory by designing to survive stacked worst-case scenarios. Additionally, the conventional heat shield design and margin process offers very little insight into the risk of over-temperature during flight and the corresponding reliability of the heat shield performance. A probabilistic margin process can be used to appropriately margin the thermal protection system based on rigorously calculated risk of failure. This probabilistic margin process allows engineers to make informed aeroshell design, entry-trajectory design, and risk trades while preventing excessive margin from being applied. This study presents the methods of the probabilistic margin process and how the uncertainty analysis is used to determine the reliability of the entry vehicle thermal protection system and associated risks of failure.

Tobin, Steven A.↗

Comparison of OVERFLOW Computational and Experimental Results of the CobraMRV Mars Entry Vehicle Concept during Supersonic Retropropulsion

The CFD solver Overflow was used to simulate the CobraMRV undergoing supersonic retropropulsion (SRP) in the Langley Unitary Plan Wind Tunnel as part of a CFD and wind tunnel integration effort. Selection of numerical methods and resulting comparisons to selected tunnel conditions of interest are detailed. Comparisons of mean pressures with static taps and pressure-sensitive paint are provided for multiple SST-based turbulence models. URANS predicitons of heat shield pressures at high thrust conditions are poor compared to TMRC and DES predictions. Comparisons to experimental measurements of pressure fluctuations indicate complex relationships between heat shield unsteadiness, flight Mach number, and engine thrust coefficient. Bow shock topology and shock cell structure between experimental and OVERFLOW data show good agreement in Schlieren imaging. Recommendations for future investigation into flow field unsteadiness and turbulence models are suggested.

CFD↗