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An analytical approach is presented for computing the flow fields, energy fluxes, and heat shield requirements for Saturn probes since total simulation of the shock layer is not feasible. The governing mechanisms are examined and uncoupled, and then put together. Experimental and theoretical inputs are synthesized to provide the necessary information for the heat shield computation.
The Orion Aerosciences program at NASA Langley has played a central role in advancing the aerodynamic and aeroheating prediction capabilities required for the Orion crew vehicle’s return from deep space. This presentation provides a technical overview of aerosciences contributions spanning Exploration Flight Test-1 (EFT-1), Artemis I, and the ongoing post-flight analysis of Artemis II. EFT-1 provided the first high-energy entry dataset for Orion, enabling critical validation of aerodynamic force and moment predictions, static and dynamic stability characteristics, and aeroheating environments at relevant flight Mach and Reynolds numbers. Flight-derived pressure data were used to refine the Flush Air Data System (FADS) methodology for atmospheric density reconstruction and to improve Best Estimated Trajectory (BET) solutions. The EFT-1 data also offered key insights into heat shield performance, including char layer recession, in-depth thermal response, and material retention behavior under flight conditions, informing updates to both thermal response models and uncertainty quantification practices. Building on EFT-1, Artemis I extended the database to true lunar-return conditions. Observations of heat shield performance, including localized char loss, bondline response, and recession variability, provided an unprecedented opportunity to reassess Thermal Protection System (TPS) and aeroheating modeling assumptions. Aerodynamic reconstruction efforts incorporated improved FADS calibration, enhanced atmospheric modeling, and refined force and moment databases to reduce trajectory and load uncertainties. Aeroheating comparisons between pre-flight predictions and flight data enabled targeted model updates, particularly in transitional flow environments and wake heating regions. For Artemis II, these lessons were systematically incorporated into the pre-flight prediction process. Updates included refined aerodynamic databases anchored to flight-validated corrections, improved density estimation and BET methodologies using enhanced database interpolation algorithm and FADS modeling, and revised aeroheating design environments informed by Artemis I material response observations. By the time of the workshop, Artemis II post-flight analysis will be underway, and preliminary findings will be presented where available, including early comparisons of aerodynamic reconstruction, atmospheric density estimation, and thermal protection system performance relative to updated predictions. Collectively, this body of work is a testament to the dedicated and multidisciplinary team whose sustained efforts have contributed to the program’s success and to the progressive maturation of Orion aerosciences modeling through numerical modeling, ground and flight data assimilation. The integrated advancement of aerodynamics, trajectory reconstruction, FADS-based density estimation, and aeroheating analysis has reduced predictive uncertainty and strengthened confidence for future crewed lunar and deep-space missions.
The effect of nonequilibrium flow chemistry on the surface temperature distribution over the forebody heat shield on the Aeroassisted Flight Experiment (AFE) vehicle was investigated using a reacting boundary-layer code. Computations were performed by using boundary-layer-edge properties determined from global iterations between the boundary-layer code and flow field solutions from a viscous shock layer (VSL) and a full Navier-Stokes solution. Surface temperature distribution over the AFE heat shield was calculated for two flight conditions during a nominal AFE trajectory. This study indicates that the surface temperature distribution is sensitive to the nonequilibrium chemistry in the shock layer. Heating distributions over the AFE forebody calculated using nonequilibrium edge properties were similar to values calculated using the VSL program.
The Mars Science Laboratory (MSL) vehicle utilized a heat shield constructed from NASA’s Phenolic-Impregnated Carbon Ablator (PICA) material to protect the main structure from the high enthalpy environment encountered during hypersonic atmospheric entry. During the vehicle’s descent through Martian atmosphere, multiple thermocouples embedded within the heat shield captured in-depth material temperature data that allow for studies to be conducted on current material response reconstruction tools. In the present work, material temperature data obtained from thermocouples within the MISP-4 plug (MEDLI (Mars Science Laboratory Entry, Descent, and Landing Instrument) Integrated Sensor Plug) are utilized in the calibration of Theoretical Ablative Composite for Open Testing (TACOT) model parameters in conjunction with NASA’s Porous material Analysis Toolbox (PATO) through Bayesian inference where uncertainty due to parametric, modeling, and experimental sources is simultaneously quantified. Prior to the study, a sensitivity analysis is performed through computation of the robust Sobol indices in an effort to study the relationship between input space and model response and to reduce the dimensionality of the statistical inverse problem. The Bayesian inference methodology necessitates an a-priori choice to be made for the uncertainty model for which numerous possibilities are available. Across most works, however, only basic additive or multiplicative models are utilized with pre-defined magnitudes of uncertainty based on a-priori knowledge or to-be-calibrated multipliers of static covariance matrix structures. The present effort explores the effects of informed uncertainty models, ones with temporal dependence that are simultaneously calibrated through Bayesian inference, on calibrated results for parameters that make up the uncertain input space.
For the reentry heating of 70-degree blunt sphere-cones entering Mars at velocities in excess of 6 km/sec, a study was performed to determine the magnitude of both convective and catalytic heating on the cone forebody. Case studies of the peak heating conditions for the current NASA Mars Pathfinder entry probe, as well as the peak heating conditions of the proposed NASA Mars 2001 aerobraking orbiter mission were performed. Since the actual behavior of the chemical recombination of Mars atmosphere hypersonic shock layer species on heat shield materials is not known, and no experimental studies of any consequence have been done to determine surface reaction rates for the CO2 system, a parametric analysis of various reaction schemes and surface catalytic mechanistic models was performed. In many cases the actual Mars entry probe will have a heat shield composed of an ablative material which can either partially or completely preclude the existence of catalytic surface recombination phenomena. The extent of this blockage effect has not been examined at this time and is not considered in this effort. Instead only non-ablative computations are performed to separately evaluate the full extent of the surface catalysis and related diffusional phenomena. Parametric studies include peak heating point comparisons of non-catalytic, partially catalytic and fully catalytic total surface heat transfer for three difference surface recombination catalytic mechanisms (with and without simultaneous CO + O and O + O recombination) as well as with different species diffusion models. Diffusion model studies include constant Schmidt number (equal diffusivities) and the bifurcation, approximate multi-component diffusion model. Since the gas phase reaction kinetics for the Mars CO2 based atmosphere have also not been validated, the effect of two different (fast and slow) sets of gas kinetics on heat transfer is presented.
A flight-weight radiative and actively cooled honeycomb sandwich panel (RACP) was subjected to multiple cycles of both radiant and aerothermal heating. The 0.61 m by 1.22 m test specimen incorporated essential features of a full scale 0.61 m by 6.10 m RACP designed to withstand a heat flux of 136 kW/sq m. The panel consisted of heat shields, a thin layer of high temperature insulation, and an aluminum honeycomb sandwich panel with coolant tubes next to the sandwich skin. A 60/40 mass solution of ethylene glycol/water was used to cool the panel which successfully withstood a total of 3.5 hr of radiant heating and 137 sec exposure to an M = 6.6 test stream. Heat shield temperatures reached 1080 K (1945 deg R), and cooled-panel temperatures reached 382 K (687 deg R) midway between coolant tubes. Simulation of the full scale panel indicated that the full scale RACP would perform as expected. The tests revealed no evidence of coolant leakage or hot gas ingress which would seriously degrade the RACP performance.
The descent module (DM) of the ISS Soyuz vehicle is covered by thermal protection system (TPS) materials that provide protection from heating conditions experienced during reentry. Damage and penetration of these materials by micrometeoroid and orbital debris (MMOD) impacts could result in loss of vehicle during return phases of the mission. The descent module heat shield has relatively thick TPS and is protected by the instrument-service module. The TPS materials on the conical sides of the descent module (referred to as backshell in this test plan) are exposed to more MMOD impacts and are relatively thin compared to the heat shield. This test program provides hypervelocity impact (HVI) data on materials similar in composition and density to the Soyuz TPS on the backshell of the vehicle. Data from this test program was used to update ballistic limit equations used in Soyuz TPS penetration risk assessments. The impact testing was coordinated by the NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Group [1] in Houston, Texas. The HVI testing was conducted at the NASA-JSC White Sands Hypervelocity Impact Test Facility (WSTF) at Las Cruces, New Mexico. Figure
Analytical studies had found the employment of an aerobraking trajectory for return of a reusable Space Tug from geosynchronous missions to be feasible and practical. To establish the minimum-weight ablative dome heat shield, trajectories involving 2 and 30 perigee passes were investigated both analytically and by plasma arc testing. Silicone-base ablators with densities of 15, 30, and 50 lb/cu ft were selected for evaluation. All models withstood the multipass exposures without deleterius surface recession or char erosion. Dome heat shield weights based on optimum ablative compositions indicated that ablators are a highly efficient thermal protection system for these missions.
With the successful flight test of the Orion Multipurpose Crew Vehicle last December, NASA is well on its way to sending humans into deep space with the ultimate goal of putting astronauts on Mars in the 2030s. Orion will receive some upgrades for its next launch in 2018 including a newly developed 3D quartz / cyanate ester composite material for the compression pad. Multiple pad locations in the heat shield serve as a part of the mechanism for holding the Crew and Service Modules together during most mission phases prior to separation followed by Earth re-entry of the Crew Module. Thus the compression pad must survive structural and aerothermal loads, and protect the adjascent structure and heat shield materials from over-heating.This paper describes the approach used for developing the new 3D composite, including continuous 3D weaving on an automated loom followed by resin transfer molding. Mechanical, thermal, arc jet ,and stress relaxation testing of the 3D composite are also described.
Concurrent engineering offers a great many benefits to engineers and mission designers throughout the world of aerospace. The only downside of concurrent engineering, and this is somewhat unavoidable, is that you don’t know the results of a design session until the end when it is completed. Usually, this is not a problem – you wouldn’t start building a spacecraft before the design is finished. However, within mass and cost constrained systems, you may end up with a final design that although technically sound – is not feasible due to mass or cost limits. Employing in-session mass and cost models with flexible inputs that refine their estimates and variance as more detailed information comes in throughout a design session allows major design changes to be made when the probability of breaching a mass or cost cap exceeds a threshold level. This enables mission designers to re-focus the study, and avoid spending 3-days with 15 engineers designing a non-feasible mission. By understanding key correlations and nested relationships within mass or cost, and specifically mass or cost allocations per mission element by mission type, it’s possible to get flexible-input, statistically based mass and cost estimates very early in the design process. Baseline models are seeded using mission characteristics and general parameters (outer planetary orbiter-probe mission, $500M cost cap for example) to provide a rough estimate of the expected mass or cost. As information gets solidified during the session, it gets added to the model and the estimates are updated. Continuing the orbiter-probe mission example, modeling probe heat shield cost as a percent of total probe cost, and probe cost as a percent of total flight system cost, and total flight system cost as a percent of total mission cost allows a design team to roll-up solidified information to estimate the probability of fitting within a mass or cost constraint early in a concurrent design session. When only the heat shield cost is known, the variance of the final estimate is higher, whereas when the full probe gets defined, naturally, the variance of the estimate decreases. A methodology, model, verification and demo implementation for cost limit breach are presented.
The Mars Science Laboratory (MSL) was protected during entry into the Martian atmosphere by a thermal protection system that used NASA’s Phenolic Impregnated Carbon Ablator (PICA). The heat shield of the probe was instrumented with the Mars Entry Descent and Landing Instrument (MEDLI) suite of sensors. MEDLI Integrated Sensor Plugs (MISP) included thermocouples that measured in-depth temperatures at various locations on the heatshield. The flight data has been used as a benchmark for validating ablation codes within NASA. This work seeks to refine the estimate of the material properties for the MSL heat shield and the aerothermal environment during Mars entry using estimation methods in DAKOTA on the temperature data obtained from MEDLI.
A low-temperature approximate simulation for the sublimation of a graphite heat shield under Jovian entry conditions is studied. A set of algebraic equations is derived to approximate the governing equation and boundary conditions, based on order-of-magnitude analysis. Characteristic quantities such as the wall temperature and the subliming velocity are predicted. Similarity parameters that are needed to simulate the most dominant phenomena of the Jovian entry flow are also given. An approximate simulation of the sublimation of the graphite heat shield is performed with an air-dry-ice model. The simulation with the air-dry-ice model may be carried out experimentally at a lower temperature of 3000 to 6000 K instead of the entry temperature of 14,000 K. The rate of graphite sublimation predicted by the present algebraic approximation agrees to the order of magnitude with extrapolated data. The limitations of the simulation method and its utility are discussed.
A low density polyimide foam material was tested in an arc tunnel to determine its potential for heat shield application on aerospace vehicles. The results show that the material has some reuse potential at surface temperatures as high as 750 K. When a black refractory paint was applied to the surface of the material, the surface recession was negligible at 750 K. An analytical thermal conductivity was derived for this material which, combined with measured thermal property values, can be used to make preliminary design thickness calculations for heat shield applications.
The Orion Crew Exploration Vehicle (CEV) was originally under development to provide crew transport to the International Space Station after the retirement of the Space Shuttle, and to provide a means for the eventual return of astronauts to the Moon. With the current changes in the future direction of the United States human exploration programs, the focus of the Orion project has shifted to the project s first orbital flight test, designated Orion Flight Test 1 (OFT-1). The OFT-1 is currently planned for launch in July 2013 and will demonstrate the Orion vehicle s capability for performing missions in low Earth orbit (LEO), as well as extensibility beyond LEO for select, critical areas. Among the key flight test objectives are those related to validation of the re-entry aerodynamic and aerothermal environments, and the performance of the thermal protection system (TPS) when exposed to these environments. A specific flight test trajectory has been selected to provide a high energy entry beyond that which would be experienced during a typical low Earth orbit return, given the constraints imposed by the possible launch vehicles. This trajectory resulted from a trade study that considered the relative benefit of conflicting objectives from multiple subsystems, and sought to provide the maximum integrated benefit to the re-entry state-of-the-art. In particular, the trajectory was designed to provide: a significant, measureable radiative heat flux to the windward surface; data on boundary transition from laminar to turbulent flow; and data on catalytic heating overshoot on non-ablating TPS. In order to obtain the necessary flight test data during OFT-1, the vehicle will need to have an adequate quantity of instrumentation. A collection of instrumentation is being developed for integration in the OFT-1 TPS. In part, this instrumentation builds upon the work performed for the Mars Science Laboratory Entry, Descent and Landing Instrument (MEDLI) suite to instrument the OFT-1 ablative heat shield. The MEDLI integrated sensor plugs and pressure sensors will be adapted for compatibility with the Orion TPS design. The sensor plugs will provide in-depth temperature data to support aerothermal and TPS model correlation, and the pressure sensors will provide a flush air data system for validation of the entry and descent aerodynamic environments. In addition, a radiometer design will be matured to measure the radiative component of the reentry heating at two locations on the heat shield. For the back shell, surface thermocouple and pressure port designs will be developed and applied which build upon the heritage of the Space Shuttle Program for instrumentation of reusable surface insulation (RSI) tiles. The quantity and location of the sensors has been determined to balance the needs of the reentry disciplines with the demands of the hardware development, manufacturing and integration. Measurements which provided low relative value and presented significant engineering development effort were, unfortunately, eliminated. The final TPS instrumentation has been optimized to target priority test objectives. The data obtained will serve to provide a better understanding of reentry environments for the Orion capsule design, reduce margins, and potentially reduce TPS mass or provide TPS extensibility for alternative missions.
The effects of dust particle impacts on the erosion of the heat shield were estimated for a 26 m diameter aerobraking vehicle entering the Mars atmosphere at 8.6 km/sec. An explicit Navier-Stokes code was used to compute the flow field about the vehicle for the actual Martian atmospheric composition at a speed of 7.5 km/sec. The deceleration and melting of the dust particles within the forebody shock-layer was computed for dust spherules having initial diameters from 3 to 10 microns. Two heat shield materials were considered: Shuttle tiles with glassy surfaces and a low-density ablator known as Avcoat.
While developing the aerodynamic database for the Orion spacecraft, the low-speed flight regime (transonic and below) proved to be the most difficult to predict and measure accurately. The flow over the capsule heat shield in descent flight was particularly troublesome for both computational and experimental efforts due to its unsteady nature and uncertainty about the boundary layer state. The data described here were acquired as part of a study to improve the understanding of the overall flow around a generic capsule. The unsteady pressure measurements acquired on a generic capsule shape are presented along with a discussion about the effects of various flight conditions and heat-shield surface roughness on the resulting pressure fluctuations.
The dimensions of aerobrakes and associated heat shields are calculated as a fraction of the vehicle mass required for a high-velocity manned Mars entry. The entry speed and deceleration limit are assumed to be 8.6 km/sec and 5 earth g, respectively, to consider vehicles with low lift-drag ratio (L/D) and ballistic coefficients of 100 and 200 kg/sq m, as well as a vehicle with a medium L/D and a ballistic coefficient of 375 kg/sq m. The aerobrake mass plus the heat shield divided by an optimized, blunt-shaped vehicle's total mass is 15 and 13 percent for ballistic coefficients of 100 and 200 kg/sq m, respectively. For a winged vehicle the mass fraction is 17 percent because the higher ballistic coefficient requires more thermal protection to account for the greater temperatures generated. It is concluded that aerobraking is more efficient than propulsive braking because the mass fraction for a propulsive system would be 4 or 5 times greater than those calculated for aerobraking.
Arc-jet facilities play a major role in the development of heat shield materials for entry vehicles because they are capable of producing representative high-enthalpy flow environments. Arc-jet test data is used to certify material performance for a particular mission and to validate or calibrate models of material response during atmospheric entry. Materials used on missions entering Earth s atmosphere are certified in an arc-jet using a simulated air entry environment. Materials used on missions entering the Martian atmosphere should be certified in an arc-jet using a simulated Martian atmosphere entry environment, which requires the use of carbon dioxide. Carbon dioxide has not been used as a test gas in a United States arc-jet facility since the early 1970 s during the certification of materials for the Viking Missions. Materials certified for the Viking missions have been used on every entry mission to Mars since that time. The use of carbon dioxide as a test gas in an arc-jet is again of interest to the thermal protection system community for certification of new heat shield materials that can increase the landed mass capability for Mars bound missions beyond that of Viking and Pathfinder. This paper describes the modification, operation, and performance of the Hypersonic Materials Environmental Test System (HYMETS) arc-jet facility with carbon dioxide as a test gas. A basic comparison of heat fluxes, various bulk properties, and performance characteristics for various Earth and Martian entry environments in HYMETS is provided. The Earth and Martian entry environments consist of a standard Earth atmosphere, an oxygen-rich Earth atmosphere, and a simulated Martian atmosphere. Finally, a preliminary comparison of the HYMETS arc-jet facility to several European plasma facilities is made to place the HYMETS facility in a more global context of arc-jet testing capability.