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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 397 records · Page 22
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NASA NTRS2006

Lightweight Ablative and Ceramic Thermal Protection System Materials for NASA Exploration Systems Vehicles

As a collaborative effort among NASA Centers, the "Lightweight Nonmetallic Thermal Protection Materials Technology" Project was set up to assist mission/vehicle design trade studies, to support risk reduction in thermal protection system (TPS) material selections, to facilitate vehicle mass optimization, and to aid development of human-rated TPS qualification and certification plans. Missions performing aerocapture, aerobraking, or direct aeroentry rely on advanced heatshields that allow reductions in spacecraft mass by minimizing propellant requirements. Information will be presented on candidate materials for such reentry approaches and on screening tests conducted (material property and space environmental effects tests) to evaluate viable candidates. Seventeen materials, in three classes (ablatives, tiles, and ceramic matrix composites), were studied. In additional to physical, mechanical, and thermal property tests, high heat flux laser tests and simulated-reentry oxidation tests were performed. Space environmental effects testing, which included exposures to electrons, atomic oxygen, and hypervelocity impacts, was also conducted.

Valentine, Peter G.↗
NASA NTRSDate not supplied

PPW 2022 Short Course Introduction to Aerocapture, Entry, Descent, and Landing: Computational Materials

Computational materials science encompasses modeling and simulation techniques that are used to improve our understanding of materials from the atomic to macroscopic scales. This talk will focus on recent applications of computational materials science to ablative thermal protection materials, including heritage PICA and state-of-the-art woven materials like HEEET. Development of advanced molecular, microscopic, and mesoscopic models will be discussed.

phenolic↗
NASA NTRSDate not supplied

Segmentation of Lightweight Ablator Micro-Tomography Using Deep Learning

Ablative thermal protection systems (TPS) are essential for high speed entry of planetary atmospheres, such as those of Earth and Mars. Upon entry the kinetic energy of the spacecraft is converted into thermal energy, leading to high heat fluxes at the wall of the craft. Because of this extreme heating, a robust ablative TPS material must be selected. A common material selection today is phenolic-impregnated carbon ablator (PICA), which is a low-density carbon material known for producing dust that is not suitable to a cleanroom environment. To mitigate dust created by a PICA heatshield, a silicone-based spray called NuSil is applied to the surface of the TPS, creating PICA-NuSil (PICA-N). PICA-N has been observed to have a different material response from regular PICA during high enthalpy flow testing, producing surface temperatures up to 200K less than those seen for PICA [1]. To better understand this phenomenon, it is critical that robust methods of PICA-N material characterization are developed. The purpose of this project is to investigate Object Research Systems’ (ORS) Dragonfly deep learning tools as a means of accurately segmenting and characterizing PICA-N. Systematic testing of this software has shown that Dragonfly deep learning tools have strong potential for accurate segmentation/ characterization of PICA-N and other TPS materials.

Micro-tomography↗
NASA NTRS2011

Fracture in Phenolic Impregnated Carbon Ablator

The thermal protection materials used for spacecraft heat shields are subjected to various thermal-mechanical loads during an atmospheric reentry which can threaten the structural integrity of the system. This paper discusses the development of a novel technique to understand the failure mechanisms inside the thermal protection material, Phenolic Impregnated Carbon Ablator (PICA). PICA has successfully flown on the Stardust spacecraft and was the TPS material chosen for the Mars Science Laboratory (MSL), that will fly in 2011. Although PICA has good thermal properties, structurally, it is a weak material. To thoroughly understand failure in PICA, experiments were performed using FiberForm(Registered TradeMark) (precursor of PICA), virgin and furnace-charred PICA. Several small samples were tested inside an electron microscope to investigate the failure mechanisms. Micrographs were obtained before and after the failure in order to study crack initiation and growth. Videos were obtained to capture failure mechanisms in real time. Stress-strain data was obtained simultaneously for all the samples with the help of a data acquisition system, integrated to the mechanical stages. It was found that cracks initiated and grew in the FiberForm when a critical stress limit was reached such that the carbon fibers separated from the binder. However, both for virgin and charred PICA, crack initiation and growth occurred in the matrix (phenolic) phase. Both virgin and charred PICA showed greater strength values compared to FiberForm coupons, confirming that the presence of the porous matrix helps in absorbing the fracture energy.

Agrawal, Parul↗
NASA NTRS2005

Pulse energy dependence of subcellular dissection by femtosecond laser pulses

Precise dissection of cells with ultrashort laser pulses requires a clear understanding of how the onset and extent of ablation (i.e., the removal of material) depends on pulse energy. We carried out a systematic study of the energy dependence of the plasma-mediated ablation of fluorescently-labeled subcellular structures in the cytoskeleton and nuclei of fixed endothelial cells using femtosecond, near-infrared laser pulses focused through a high-numerical aperture objective lens (1.4 NA). We find that the energy threshold for photobleaching lies between 0.9 and 1.7 nJ. By comparing the changes in fluorescence with the actual material loss determined by electron microscopy, we find that the threshold for true material ablation is about 20% higher than the photobleaching threshold. This information makes it possible to use the fluorescence to determine the onset of true material ablation without resorting to electron microscopy. We confirm the precision of this technique by severing a single microtubule without disrupting the neighboring microtubules, less than 1 micrometer away. c2005 Optical Society of America.

Non-NASA Center↗
NASA NTRS1998

CFD Modelling of Bore Erosion in Two-Stage Light Gas Guns

A well-validated quasi-one-dimensional computational fluid dynamics (CFD) code for the analysis of the internal ballistics of two-stage light gas guns is modified to explicitly calculate the ablation of steel from the gun bore and the incorporation of the ablated wall material into the hydrogen working cas. The modified code is used to model 45 shots made with the NASA Ames 0.5 inch light gas gun over an extremely wide variety of gun operating conditions. Good agreement is found between the experimental and theoretical piston velocities (maximum errors of +/-2% to +/-6%) and maximum powder pressures (maximum errors of +/-10% with good igniters). Overall, the agreement between the experimental and numerically calculated gun erosion values (within a factor of 2) was judged to be reasonably good, considering the complexity of the processes modelled. Experimental muzzle velocities agree very well (maximum errors of 0.5-0.7 km/sec) with theoretical muzzle velocities calculated with loading of the hydrogen gas with the ablated barrel wall material. Comparison of results for pump tube volumes of 100%, 60% and 40% of an initial benchmark value show that, at the higher muzzle velocities, operation at 40% pump tube volume produces much lower hydrogen loading and gun erosion and substantially lower maximum pressures in the gun. Large muzzle velocity gains (2.4-5.4 km/sec) are predicted upon driving the gun harder (that is, upon using, higher powder loads and/or lower hydrogen fill pressures) when hydrogen loading is neglected; much smaller muzzle velocity gains (1.1-2.2 km/sec) are predicted when hydrogen loading is taken into account. These smaller predicted velocity gains agree well with those achieved in practice. CFD snapshots of the hydrogen mass fraction, density and pressure of the in-bore medium are presented for a very erosive shot.

Bogdanoff, D. W.↗
NASA NTRSDate not supplied

Identification and Study of Validation Level Test Cases for Computational Modeling of Non-Charring Ablators

Computational modeling of Thermal Protection System (TPS) materials, used for aerospace applications, provides numerous advantages in preliminary selection and design of a heatshield material and shape for atmospheric entry vehicles. However, to serve as a reliable tool for prediction of material thermal and ablative behavior, the modeling approach needs to be validated against real experimental and flight data, preferably at a range of applied conditions. The validation study is typically very complex as it requires reliable measured data not only for the material thermal response and surface recession, but also well characterized environmental conditions. The validation problem becomes even more complex when the material thermal response is dictated by multi-physics effects such as solid conduction, in-depth thermal decomposition, pyrolysis gas flow and chemical reactions. The multi-physics effects complicate not only the modeling effort, but also the experimental measurement for validation of various aspects of the highly coupled problem. In this study, an attempt is made to identify suitable experimental data that could serve as a source for validation of material thermal response modeling tools. To reduce the computational complexity, this study focuses only on non-charring ablators, where the material thermal response could be modeled with a single governing equation for solid conduction and the ablation is limited only to the surface of the material. With a well characterized and publicly available experimental data being sparse, the study is limited in presenting test cases for only three materials: camphor, graphite and FiberForm® in the sequence of increased modeling complexity. Graphite is a commonly used TPS material for aerospace applications, both for leading edges of high-speed vehicles and internal insulation of solid rocket motors. FiberForm® is a porous carbon pre-form used in preparation of the well known PICA material Tran et al. [1996]. Inclusion of camphor into the list is conditioned with the relative simplicity in modeling the material thermal and chemical response and the low-enthalpy flow environment. In addition, camphor has been used as a simple test material for study of flow transition behavior by Stock and Ginoux [1973] and assessment of a heatshield shape change at flight relevant conditions by Rotondi et al. [2022]. In this work, the identified experimental data was extracted from the public literature and test cases that yet have been published. As it was found from the review, not a single test case contains an exhaustive set of data that would validate every aspect of the material physics. However, in the data collected, various aspects of the material behavior can be still validated, such as surface and in-depth temperature, amount of recession and a shape change. The identified experimental data for each case is accompanied with a characterized flow environment and simulated boundary conditions predicted by a Data-Parallel Line Relaxation (DPLR) code Wright et al. [1998]. In addition, material thermal response numerical simulations in each test case are performed with Kentucky Aerothermodynamics and Thermal Response System (KATS-MR) Zibitsker et al. [2022] providing a comparative study and a sanity check for the proposed validation data. Sample results from the performed numerical study are shown below. Figure 1 shows distribution of surface heat flux and pressure values on a hemi-cylinder model made of FiberForm® and tested in HyMETS arc-jet facility. The results are shown for the high pressure condition among the two tests. Flow simulation was performed with DPLR code on a quarter of original geometry. In the figure, the quarter shape was mirrored across zx and xy planes to show the complete distribution. Figure 2 shows the material response results for the high pressure case (7500 Pa), simulated with KATS-MR and a comparison to the experimental data for the surface temperature and shape shape. The simulation was performed on a 2-D slice, extracted in the xy plane at the middle of the sample. Figure 3 shows the material response simulation for the low pressure case (3500 Pa) and a comparison to the experimental data for surface temperature and shape change.

ablation↗
NASA NTRSDate not supplied

Validating Arc-jet Condition Targets Using Inverse 1D Material Response Models

Experiments were conducted using both the Interaction Heating Facility (IHF) and Aerodynamic Heating Facility (AHF), two hypersonic arc-jet facilities at NASA Ames. These tests were run to understand the material response of ablative thermal protection system materials by exposing them to high-enthalpy flows. Using thermocouple data from the materials, test conditions were inversely determined and compared with expected results from a one-dimensional model using facility target conditions; this allowed an approximate environmental scale factor to be determined and applied to more accurately predict material response in additional tests.

material response↗
NASA NTRS2012

A Statistics-Based Material Property Analysis to Support TPS Characterization

Accurate characterization of entry capsule heat shield material properties is a critical component in modeling and simulating Thermal Protection System (TPS) response in a prescribed aerothermal environment. The thermal decomposition of the TPS material during the pyrolysis and charring processes is poorly characterized and typically results in large uncertainties in material properties as inputs for ablation models. These material property uncertainties contribute to large design margins on flight systems and cloud re- construction efforts for data collected during flight and ground testing, making revision to existing models for entry systems more challenging. The analysis presented in this work quantifies how material property uncertainties propagate through an ablation model and guides an experimental test regimen aimed at reducing these uncertainties and characterizing the dependencies between properties in the virgin and charred states for a Phenolic Impregnated Carbon Ablator (PICA) based TPS. A sensitivity analysis identifies how the high-fidelity model behaves in the expected flight environment, while a Monte Carlo based uncertainty propagation strategy is used to quantify the expected spread in the in-depth temperature response of the TPS. An examination of how perturbations to the input probability density functions affect output temperature statistics is accomplished using a Kriging response surface of the high-fidelity model. Simulations are based on capsule configuration and aerothermal environments expected during the Mars Science Laboratory (MSL) entry sequence. We identify and rank primary sources of uncertainty from material properties in a flight-relevant environment, show the dependence on spatial orientation and in-depth location on those uncertainty contributors, and quantify how sensitive the expected results are.

Copeland, Sean R.↗
NASA NTRS2010

Thermal Protection System (Heat Shield) Development - Advanced Development Project

The Orion Thermal Protection System (TPS) ADP was a 3 1/2 year effort to develop ablative TPS materials for the Orion crew capsule. The ADP was motivated by the lack of available ablative TPS's. The TPS ADP pursued a competitive phased development strategy with succeeding rounds of development, testing and down selections. The Project raised the technology readiness level (TRL) of 8 different TPS materials from 5 different commercial vendors, eventual down selecting to a single material system for the Orion heat shield. In addition to providing a heat shield material and design for Orion on time and on budget, the Project accomplished the following: 1) Re-invigorated TPS industry & re-established a NASA competency to respond to future TPS needs; 2) Identified a potentially catastrophic problem with the planned MSL heat shield, and provided a viable, high TRL alternate heat shield design option; and 3) Transferred mature heat shield material and design options to the commercial space industry, including TPS technology information for the SpaceX Dragon capsule.

Kowal, T. John↗