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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Material Response Modeling of Ablative Thermal Protection Systems using PATO

Developing thermal protection systems (TPS) for future space vehicles involves an extensive design and test cycle. A key component of the cycle is determining margins for a safe design that rely on confidence in the performance of the TPS. Predicting the complicated multiphysics phenomena that occur during atmospheric entry requires high-fidelity modeling tools. To this end, the Porous-material Analysis Toolbox based on OpenFOAM (PATO) has been developed. PATO is an open-source software for computing material response of reactive porous materials submitted to high-temperature environments. Recent applications of PATO include computation of the full heatshield 3D material response from the Mars Science Laboratory atmospheric entry and ablation during arc jet testing. Current efforts are underway to loosely couple PATO with other discipline specialized codes including hypersonic computational fluid dynamics (CFD) to assess the effects of pyrolysis-gas blowing into the boundary layer and computational solid mechanics to address modeling of mechanical erosion. Surface phenomena modeling capabilities to address the effects of silicone-based coatings applied to the TPS during flight preparation are also being added.

Thermal Protection Systems↗
NASA NTRS1977

Intumescent-ablators as improved thermal protection materials

Nitroaromatic amine-based intumescent coatings were improved with regard to their thermal protection ability by adding endothermic decomposing fillers with endotherms at or near the exothermic reaction of the intumescent agent, since the effectiveness of the intumescent coatings without fillers is reduced by the exothermic behavior of the coatings during thermal activation. Fillers were dispersed directly in the base coating. Potassium fluoborate, ammonium fluoborate, zinc borate, and ammonium oxalate function as endothermic ablative materials at specific temperature regions, and also enhance the char formation during the intumescent process.

Sawko, P. M.↗
NASA NTRSDate not supplied

Multiscale Modeling of Woven Ablative Thermal Protection System Materials

The NASA Entry Systems Modeling project maintains a portfolio of computational model and tool development activities focused on reducing performance uncertainties in ablative Thermal Protection System (TPS) materials for NASA missions. The development activities span material scale and strive to allow microstructural characterization of material structure and properties, mesoscale analyses of damage, and macroscale evaluation of heatshield performance and recession in a given aerothermodynamic environment. This talk will detail the application of developed capabilities at all three scales to the woven TPS material that the Agency has selected as the heatshield for the Mars Sample Return Earth Entry System (MSR-EES) mission – 3D Mid-Density Carbon Phenolic (3MDCP). Each of the applications focuses on driving down uncertainties in material performance and thus risk for MSR-EES and other future missions that may leverage woven TPS. At the microscale, machine learning techniques are used to characterize images from destructive microscopy and inform structural variability. At the mesoscale, Lagrangian techniques are used to simulate ballistic impact and interpret damage modes noted in experiments. At the macroscale, coupled flow-material response techniques are validated by Arc Jet testing to enable heatshield design for missions with massive ablation.

Justin B Haskins↗
DOE OSTI2026

Improving indirect-drive ablator performance through pulse shaping and material selection in double shell implosions

The double shell path to inertially confined volumetric thermonuclear burn relies on efficient kinetic energy transfer from an outer ablator shell to an inner shell containing DT fuel at implosion velocities near 250 km/s. In order to experimentally realize adequate compression, target imperfections and assembly features must be tightly controlled. Pulse shape and ablator material are critical design choices that impact all aspects of the implosion. In this article, we evaluate three designs: an Al ablator with single-shock radiation drive, a CH ablator with single-shock drive, and a CH ablator with reduced-adiabat 2-shock drive. All designs use the same W inner (pusher) shell overcoated with a glow discharge polymer tamper and filled with liquid-density DT. One-dimensional HYDRA simulations revealed that the plastic ablator design required the use of the 2-shock drive to match the performance of the Al design. Two-dimensional simulations resolving broadband surface roughness up to modes of several hundred placed only on the ablator showed plastic to greatly outperform Al. The plastic ablator designs did exhibit higher levels of inner shell instability growth when surface roughness was only placed at the pusher/tamper interface, which was mitigated with higher foam cushion densities. A unique and additional benefit of a plastic ablator is also discussed, where heating of the ablator by Au M-band radiation is predicted to rapidly expand the hemi-shell surfaces, closing the equatorial joint gap ahead of the first shock. Taken together, the properties of the plastic ablator for indirect-drive double shell implosions appear promising in removing several long-standing fabrication challenges.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1972

Materials and design for ablative heat shields

The goal of the ablation technology program is to bring ablation research and development to a high state of readiness for application to space shuttle vehicles. Some recent results and current work in the areas of materials, designs, and refurbishment for ablative TPS are reported. Future research and development needs are also presented.

Dow, M. B.↗
NASA NTRS2013

Post-Flight Evaluation of PICA and PICA-X - Comparisons of the Stardust SRC and Space-X Dragon 1 Forebody Heatshield Materials

Phenolic Impregnated Carbon Ablator (PICA) was developed at NASA Ames Research Center. As a thermal protection material, PICA has the advantages of being able to withstand high heat fluxes with a relatively low density. This ablative material was used as the forebody heat shield material for the Stardust sample return capsule, which re-entered the Earths atmosphere in 2006. Based on PICA, SpaceX developed a variant, PICA-X, and used it as the heat shield material for its Dragon spacecraft, which successfully orbited the Earth and re-entered the atmosphere during the COTS Demo Flight 1 in 2010. Post-flight analysis was previously performed on the Stardust PICA heat shield material. Similarly, a near-stagnation core was obtained from the post-flight Dragon 1 heat shield, which was retrieved from the Pacific Ocean. Materials testing and analyses were performed on the core to evaluate its ablation performance and post-flight properties. Comparisons between PICA and PICA-X are made where applicable. Stardust and Dragon offer rare opportunities to evaluate materials post-flight - this data is beneficial in understanding material performance and also improves modeling capabilities.

PICA-X↗
NASA NTRSDate not supplied

Simulating Ordinary Chondrite (Tamdakht) Ablation at the Hypersonic Materials Environmental Test System (HyMETS) Facility.

NASA’s Science Mission Directorate (SMD) created the Asteroid Threat Assessment Project (ATAP) to inform decision-makers of risks associated with Potentially Hazardous Objects (PHOs), which may pose an existential threat to human civilization. ATAP assesses risk, in part, by developing analytical physics-based damage models which draw upon data collected during material property characterization efforts, entry simulations, hazard simulations, and ground-based arc-jet testing. Therefore, a pathfinder test campaign was con-ducted at the Hypersonic Materials Environmental Test System (HyMETS) at the NASA Langley Re-search Center to investigate the ablation mechanisms of an ordinary chondrite (Tamdakht H5) and a terrestrial analog (basalt). The HyMETS facility is a 400 kW constricted arc heater used to screen material performance under simulated aerothermal conditions of hypersonic flow.1 Facility conditions were chosen to simulate Earth entry conditions be-tween the upper-mesosphere and the lower thermo-sphere. The ablation mechanisms of Tamdakht and bas-alt are illustrated with still images collected from high-speed video cameras (fig. 1, Tamdakht). Tamdakht produces a relatively stable melt flow, as evidenced by the perpetual growth of a flange at the sidewall and the exiguous detachment of molten material into the flow. Furthermore, an inspection of high-speed video and chemical analysis of the post-test melt layer suggests that the dominant mode of mass loss for Tamdakht, at these test conditions, is expressed through the vaporization of volatiles (e.g., iron, potassium, sodium, phosphorus, and sulfur). The vaporization rates of Tamdakht are greater than basalt under the most extreme test conditions, which leads to an enhanced blowing layer, in-creased thermal shielding, and reduced recession. The ablation mechanisms of basalt are markedly different from Tamdakht and are attributed to the presence of hydrated minerals dispersed at irregular intervals throughout the silicate matrix. Rapid de-composition of secondary minerals and the subsequent formation of water lead to the ejection of the subsurface and overlying melt layer. Furthermore, the presence of water is suspected of lowering the viscosity of the melt layer resulting in increased mass loss near the edge of the test article where drag forces overcome rheological properties (fig. 1, bas-alt). Finally, the results will be discussed in the broader context of meteorite-based material response model development and the potential impact on the Asteroid Threat Assessment Project (ATAP).

Brody K. Bessire↗
NASA NTRS2002

Ablative Laser Propulsion Using Multi-Layered Material Systems

Experimental investigations are ongoing to study the force imparted to materials when subjected to laser ablation. When a laser pulse of sufficient energy density impacts a material, a small amount of the material is ablated. A torsion balance is used to measure the momentum produced by the ablation process. The balance consists of a thin metal wire with a rotating pendulum suspended in the middle. The wire is fixed at both ends. Recently, multi-layered material systems were investigated. These multi-layered materials were composed of a transparent front surface and opaque sub surface. The laser pulse penetrates the transparent outer surface with minimum photon loss and vaporizes the underlying opaque layer.

Nehls, Mary↗
NASA NTRS2006

Space Shuttle Thermal Protection System Repair Flight Experiment Induced Contamination Impacts

NASA s activities to prepare for Flight LF1 (STS-114) included development of a method to repair the Thermal Protection System (TPS) of the Orbiter s leading edge should it be damaged during ascent by impacts from foam, ice, etc . Reinforced Carbon-Carbon (RCC) is used for the leading edge TPS. The repair material that was developed is named Non- Oxide Adhesive eXperimental (NOAX). NOAX is an uncured adhesive material that acts as an ablative repair material. NOAX completes curing during the Orbiter s descent. The Thermal Protection System (TPS) Detailed Test Objective 848 (DTO 848) performed on Flight LF1 (STS-114) characterized the working life, porosity void size in a micro-gravity environment, and the on-orbit performance of the repairs to pre-damaged samples. DTO 848 is also scheduled for Flight ULF1.1 (STS-121) for further characterization of NOAX on-orbit performance. Due to the high material outgassing rates of the NOAX material and concerns with contamination impacts to optically sensitive surfaces, ASTM E 1559 outgassing tests were performed to determine NOAX condensable outgassing rates as a function of time and temperature. Sensitive surfaces of concern include the Extravehicular Mobility Unit (EMU) visor, cameras, and other sensors in proximity to the experiment during the initial time after application. This paper discusses NOAX outgassing characteristics, how the amount of deposition on optically sensitive surfaces while the NOAX is being manipulated on the pre-damaged RCC samples was determined by analysis, and how flight rules were developed to protect those optically sensitive surfaces from excessive contamination where necessary.

Smith, Kendall A.↗
NASA NTRS1978

Carbonaceous materials subjected to extreme heating - A comparison of numerical simulation and experiments

The ablation of carbonaceous materials in a hydrogen-helium stream has been simulated using a charring materials ablator computer code. These results are compared with the first ablation data to be obtained from the Ames-NASA Giant Planet Pilot Facility. Test stream diagnostics and ablation effects on convective and radiative heat transfer are discussed since these parameters constitute important input data to the numerical simulation. Graphite ablation was predicted to within 10 to 20%, and carbon-phenolic somewhat less accurately.

Davy, W. C.↗
NASA NTRSDate not supplied

Analysis of MSL/MEDLI Entry Data with Coupled CFD and Material Response

The Mars Science Laboratory (MSL) was protected during its atmospheric entry by an instrumented heatshield using NASA's Phenolic Impregnated Carbon Ablator (PICA) material [1]. PICA is a lightweight carbon fiber/polymeric resin material that offers outstanding performances for protecting probes during planetary entry. The Mars Entry Descent and Landing Instrument (MEDLI) suite on MSL offers unique in-flight validation data for models of material response and atmospheric entry. MEDLI recorded, among other things, time-resolved in-depth temperature data of PICA using thermocouple sensors assembled in the MEDLI Integrated Sensor Plugs (MISP) [2]. The objective of this work is to showcase and analyze the coupling between the material response and the aerothermal environment. As shown in Figure 1, the workflow is divided into the following steps. First, the aerothermal properties are computed in the Data Parallel Line Relaxation (DPLR) code [3] and used with the Nonequilibrium air radiation (NEQAIR) program [8] to compute radiative heating. Second, the thermal response inside the material is computed in the Porous material Analysis Toolbox based on OpenFOAM (PATO) [4,5,6] using a fixed blowing correction parameter. Third, the pyrolysis gases computed in PATO are used as inputs to a blowing boundary condition within DPLR. Fourth, the new environment properties from DPLR are used in NEQAIR to provide an updated solution, then both the updated aerothermal environment and radiative heating are used in PATO without blowing correction. The third and fourth steps are then repeated until convergence in surface temperature is obtained. Convergence in the radiative heating is generally achieved before surface temperature, at which point the radiative heating is no longer updated. Char mass loss rates are forced to zero to produce a non-receding surface condition. For early time points in the trajectory, where flow around the MSL aeroshell is rarefied, the Direct Simulation Monte Carlo (DSMC) code, SPARTA [7], is used to compute the aerothermal environment. Iteration between PATO and SPARTA is not performed due to the computational cost of DSMC simulations. Preliminary results of the coupling between PATO and DPLR for the MSL heatshield atmospheric entry model are presented in Figures 2-4 at 65 seconds after entry interface. Figure 2 shows the surface temperature results from an uncoupled simulation in PATO with the blowing correction parameter applied (left) along with the coupled surface temperature after iteration (right). Figure 3 shows the surface temperature along the centerline from windward to leeward for easier comparison. Figure 4 shows the coupled and uncoupled pyrolysis gas blowing rate. Mars 2020 used a similar heatshield consisting of PICA for thermal protection during entry, descent, and landing. In preparation for Mars 2020 post-flight analysis, the predictive material response capability is benchmarked against flight data from MEDLI. This work represents an important milestone toward the development of validated predictive capabilities for designing thermal protection systems for planetary probes.

Thermal Protection Systems↗