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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Development of 3D Woven Ablative Thermal Protection Systems (TPS) for NASA Spacecraft

The development of a new class of thermal protection system (TPS) materials known as 3D Woven TPS led by the Entry Systems and Technology Division of NASA Ames Research Center (ARC) will be discussed. This effort utilizes 3D weaving and resin infusion technologies to produce heat shield materials that are engineered and optimized for specific missions and requirements. A wide range of architectures and compositions have been produced and preliminarily tested to prove the viability and tailorability of the 3D weaving approach to TPS.

3D weaving↗
NASA NTRS1996

Emission Spectral Measurements in the Plenum of an Arc Jet Wind Tunnel

Arc jet wind tunnel facilities are used to evaluate thermal protection system materials for re-entry vehicles. The high speed, high temperature flowfield generated by the arc jet can simulate the extreme aerodynamic heating environment experienced during re-entry so that the survivability of heat shield materials and performance of various designs options can be tested. Although the re-entry heating environment can be approximated in the arc jet facility, the flowfield only partially simulates the actual re-entry flight conditions. Reynolds numbers are not matched so that surface shear stress distributions and mass transfer rates due to ablation or other mechanisms are not modeled correctly. Unlike flight conditions the arc freestream air is in non-equilibrium because of the rapid expansion that occurs in the supersonic nozzle. To properly study the actual re-entry flow environment, computational fluid dynamics, computational chemistry and radiation models must be used. Arc jet tunnel tests serve to validate these models. To perform accurate simulations inlet and boundary-conditions are needed, which come from measurements of the flowfield. The present study is concerned with measurements in the plenum region of an arc heater. In the past, conditions in the arc heater flowfield have been predicted using simulations since conventional measurement techniques could not be used in the harsh extremely high temperature environment. The present study is part of a recent push to utilize optical techniques to help better characterize the arc jet flowfields. Emission measurements have been made in the shock layer and the constrictor section of the arc heater to determine temperatures and species number densities. LIF measurements have been made in the free stream to determine temperature and velocity.

Donohue, Jim↗
NASA NTRS1984

Experimental investigation of the pulsed electrothermal (PET) thruster

Burton et al. (1982) have discussed the theory of the Pulsed Electrothermal (PET) thruster, a device which in principle can operate with 70 percent efficiency at a specific impulse of 1000 seconds and higher. It is pointed out that this level of performance would be particularly attractive for orbit raising of large satellites and other near-earth missions, which cannot be easily accomplished by chemical propulsion. The present investigation is concerned with two PET thruster operating modes. A PET thruster was built and tested on a thrust stand. Exhaust velocities for polyethylene propellant vary from 20 to 27 km/sec. Single pulse specific impulse and efficiency measurements based on ablated mass show a thruster efficiency of 37-56 percent in the time range from 1000 to 1750 seconds. It is believed that an improved design with a thruster efficiency in the range from 70 to 80 percent might be possible.

Burton, R. L.↗
NASA NTRS2002

Concentrating Antarctic Meteorites on Blue ice Fields: The Frontier Mountain Meteorite Trap

The collection of meteorites in Antarctica has greatly stimulated advancement in the field of meteoritics by providing the community with significant numbers of rare and unique meteorites types and by yielding large numbers of meteorites that sample older infall epochs (Grady et al., 1998). The majority of Antarctic meteorites are found on blue ice fields, where they are thought to be concentrated by wind and glacial drift (cf. Cassidy et al., 1992). The basic "ice flow model" describes the concentration of meteorites by the stagnation or slowing of ice as it moves against a barrier located in a zone with low snow accumulation. However, our limited knowledge of the details of the actual concentration mechanisms prevents establishing firm conclusions concerning the past meteorite flux from the Antarctic record (Zolensky, 1998). The terrestrial ages of Antarctic meteorites indicate that their concentration occurs on time scales of tens to hundreds of thousands of years (Nishiizumi et al., 1989). It is a challenge to measure a mechanism that operates so slowly, and since such time scales can span more than one glacial epoch one cannot assume that the snow accumulation rates, ice velocities and directions, etc. that are measured today are representative of those extant over the age of the trap. Testing the basic "ice flow model" therefore requires the careful measurement of meteorite locations, glacialogical ice flow data, ice thicknesses, bedrock and surface topology, ice ablation and snow accumulation rates, and mass transport by wind over an extended period of time in a location where these quantities can be interpreted in the context of past glacialogical history.

Sandford, Scott A.↗
NASA NTRS2013

Effects of Nonequilibrium Chemistry and Darcy-Forchheimer Pyrolysis Flow for Charring Ablator

The fully implicit ablation and thermal response code simulates pyrolysis and ablation of thermal protection materials and systems. The governing equations, which include energy conservation, a three-component decomposition model, and a surface energy balance, are solved with a moving grid.This work describes new modeling capabilities that are added to a special version of code. These capabilities include a time-dependent pyrolysis gas flow momentum equation with Darcy-Forchheimer terms and pyrolysis gas species conservation equations with finite rate homogeneous chemical reactions. The total energy conservation equation is also enhanced for consistency with these new additions. Two groups of parametric studies of the phenolic impregnated carbon ablator are performed. In the first group, an Orion flight environment for a proposed lunar-return trajectory is considered. In the second group, various test conditions for arcjet models are examined. The central focus of these parametric studies is to understand the effect of pyrolysis gas momentum transfer on material in-depth thermal responses with finite-rate, equilibrium, or frozen homogeneous gas chemistry. Results indicate that the presence of chemical nonequilibrium pyrolysis gas flow does not significantly alter the in-depth thermal response performance predicted using the chemical equilibrium gas model.

Chen, Yih-Kanq↗
NASA NTRSDate not supplied

3D-MAT Multi-rate Thermal Expansion and Restrained Thermal Growth

In an effort to characterize 3D Multifunctional Ablative Thermal Protection System (3D-MAT), a quartz fiber / cyanate ester composite for NASA’s Orion Multipurpose Crew Vehicle, Southern Research carried out multiple test efforts. Southern Research evaluated the coefficient of free thermal expansion at multiple heating rates in the X, Y and Z directions. To further understand the results, we further evaluated the material via Restrained Thermal Growth (RTG) in the X direction. The RTG test series involved testing via multiple procedures, resulting in an iterative process and a final conclusion.

Jay D Feldman↗
NASA NTRS2001

Real-Time Inhibitor Recession Measurements in the Space Shuttle Reusable Solid Rocket Motors

Real-time char line recession measurements were made on propellant inhibitors of the Space Shuttle Reusable Solid Rocket Motor (RSRM). The RSRM FSM-8 static test motor propellant inhibitors (composed of a rubber insulation material) were successfully instrumented with eroding potentiometers and thermocouples. The data was used to establish inhibitor recession versus time relationships. Normally, pre-fire and post-fire insulation thickness measurements establish the thermal performance of an ablating insulation material. However, post-fire inhibitor decomposition and recession measurements are complicated by the fact that most of the inhibitor is back during motor operation. It is therefore a difficult task to evaluate the thermal protection offered by the inhibitor material. Real-time measurements would help this task. The instrumentation program for this static test motor marks the first time that real-time inhibitors. This report presents that data for the center and aft field joint forward facing inhibitors. The data was primarily used to measure char line recession of the forward face of the inhibitors which provides inhibitor thickness reduction versus time data. The data was also used to estimate the inhibitor height versus time relationship during motor operation.

McWhorter, Bruce B.↗
NASA NTRS2003

Microelectromechanical Systems (MEMS) Broadband Light Source Developed

A miniature, low-power broadband light source has been developed for aerospace applications, including calibrating spectrometers and powering miniature optical sensors. The initial motivation for this research was based on flight tests of a Fabry-Perot fiberoptic temperature sensor system used to detect aircraft engine exhaust gas temperature. Although the feasibility of the sensor system was proven, the commercial light source optically powering the device was identified as a critical component requiring improvement. Problems with the light source included a long stabilization time (approximately 1 hr), a large amount of heat generation, and a large input electrical power (6.5 W). Thus, we developed a new light source to enable the use of broadband optical sensors in aerospace applications. Semiconductor chip-based light sources, such as lasers and light-emitting diodes, have a relatively narrow range of emission wavelengths in comparison to incandescent sources. Incandescent light sources emit broadband radiation from visible to infrared wavelengths; the intensity at each wavelength is determined by the filament temperature and the materials chosen for the filament and the lamp window. However, present commercial incandescent light sources are large in size and inefficient, requiring several watts of electrical power to obtain the desired optical power, and they emit a large percentage of the input power as heat that must be dissipated. The miniature light source, developed jointly by the NASA Glenn Research Center, the Jet Propulsion Laboratory, and the Lighting Innovations Institute, requires one-fifth the electrical input power of some commercial light sources, while providing similar output light power that is easily coupled to an optical fiber. Furthermore, it is small, rugged, and lightweight. Microfabrication technology was used to reduce the size, weight, power consumption, and potential cost-parameters critical to future aerospace applications. This chip-based light source has the potential for monolithic fabrication with on-chip drive electronics. Other uses for these light sources are in systems for vehicle navigation, remote sensing applications such as monitoring bridges for stress, calibration sources for spectrometers, light sources for space sensors, display lighting, addressable arrays, and industrial plant monitoring. Two methods for filament fabrication are being developed: wet-chemical etching and laser ablation. Both yield a 25-mm-thick tungsten spiral filament. The proof-of-concept filament shown was fabricated with the wet etch method. Then it was tested by heating it in a vacuum chamber using about 1.25 W of electrical power; it generated bright, blackbody radiation at approximately 2650 K. The filament was packaged in Glenn's clean-room facilities. This design uses three chips vacuum-sealed with glass tape. The bottom chip consists of a reflective film deposited on silicon, the middle chip contains a tungsten filament bonded to silicon, and the top layer is a transparent window. Lifetime testing on the package will begin shortly. The emitted optical power is expected to be approximately 1.0 W with the spectral peak at 1.1 mm.

Tuma, Margaret L.↗
DOE OSTI2026

Relief Zones Enhance the Durability of Ultrathin Membranes in Electrochemical Conversion Devices

Premature failures in electrochemical conversion systems often result when membrane electrode assemblies (MEAs) use ultrathin (≤15 μm-thick) polymer electrolyte membranes, susceptible to mechanical degradation from stress concentrations arising from device-level integration. Herein, relief zones were developed to mitigate mechanical degradation by alleviating excess and nonuniform compression across active areas. Relief zones, created through ablation of carbonaceous diffusion media, enable seamless adaptation across MEA dimensions without need for hardware modifications. Demonstrated using fuel cells as a case study, accelerated stress tests revealed a 6-fold lifetime improvement (∼1500 h) compared to conventional edge-protected MEAs, decoupling device-level engineering effects from material limitations.

accelerated stress test↗
NASA NTRS2009

Development of an On-board Failure Diagnostics and Prognostics System for Solid Rocket Booster

We develop a case breach model for the on-board fault diagnostics and prognostics system for subscale solid-rocket boosters (SRBs). The model development was motivated by recent ground firing tests, in which a deviation of measured time-traces from the predicted time-series was observed. A modified model takes into account the nozzle ablation, including the effect of roughness of the nozzle surface, the geometry of the fault, and erosion and burning of the walls of the hole in the metal case. The derived low-dimensional performance model (LDPM) of the fault can reproduce the observed time-series data very well. To verify the performance of the LDPM we build a FLUENT model of the case breach fault and demonstrate a good agreement between theoretical predictions based on the analytical solution of the model equations and the results of the FLUENT simulations. We then incorporate the derived LDPM into an inferential Bayesian framework and verify performance of the Bayesian algorithm for the diagnostics and prognostics of the case breach fault. It is shown that the obtained LDPM allows one to track parameters of the SRB during the flight in real time, to diagnose case breach fault, and to predict its values in the future. The application of the method to fault diagnostics and prognostics (FD&P) of other SRB faults modes is discussed.

Smelyanskiy, Vadim N.↗
NASA NTRSDate not supplied

NASA's Innovative Entry Systems and TPS Technologies Enabling Commercial Space Missions

For over six decades, the NASA Ames Entry Systems and Technology Division has been a cornerstone of U.S. space exploration, delivering critical atmospheric entry solutions since Project Mercury and now increasingly supporting the commercial space sector. The Division provides reliable entry system solutions through a unique blend of expertise, national facilities, and systems integration knowledge, a combination that is difficult to replicate outside a dedicated government entity. Consistently successful, the TS Division remains central to NASA’s exploration objectives and significantly contributes to the transfer of technology to the commercial space sector, supporting more than ten commercial space companies and supplying flight heatshields to three of them in the past five years. Its strengths in Thermal Protection System (TPS) materials, aerothermodynamics, ground test facilities, and Entry, Descent, and Landing (EDL) systems engineering drive rapid development and sustained U.S. competitiveness in space. The Division's expertise in reusable and ablative thermal protection systems, as well as mechanically deployable entry systems primarily developed for NASA missions, now benefits commercial space missions. This presentation will highlight the vision and needs of these commercial space companies, how NASA-invented technologies meet mission requirements, and how these technologies enable and distinguish their efforts.

Ethiraj Venkatapathy↗
NASA NTRS2016

Infrared Observations of the Orion Capsule During EFT-1 Hypersonic Reentry

High-resolution infrared observations of the Orion capsule during its atmospheric reentry on December 5, 2015 were made from a US Navy NP-3D. This aircraft, equipped with a long-range optical sensor system, tracked the capsule from Mach 10 to 7 from a distance of approximately 60 nmi. Global surface temperatures of the capsule's thermal heatshield were derived from near infrared intensity measurements. The global surface temperature measurements complemented onboard instrumentation and were invaluable to the interpretation of the in-depth thermocouple measurements which rely on inverse heat transfer methods and material response codes to infer the desired surface temperature from the sub-surface measurements. The full paper will address the motivations behind the NASA Engineering Safety Center sponsored observation and highlight premission planning processes with an emphasis on aircraft placement, optimal instrument configuration and sensor calibrations. Critical aspects of mission operations coordinated from the NASA Johnson Spaceflight Center and integration with the JSC Flight Test Management Office will be discussed. A summary of the imagery that was obtained and processed to global surface temperature will be presented. At the capsule's point of closest approach relative to the imaging system, the spatial resolution was estimated to be approximately 15-inches per pixel and was sufficient to identify localized temperature increases associated with compression pad support hardware on the heatshield. The full paper will discuss the synergy of the quantitative imagery derived temperature maps with in-situ thermocouple measurements. Comparison of limited onboard surface thermocouple data to the image derived surface temperature will be presented. The two complimentary measurements serve as an example of the effective leveraging of resources to advance the understanding of high Mach number environments associated with an ablated heatshield and provide unique data for the validation of design tools and numerical flight simulation techniques. Collaborative opportunities and technology investments in support of planned observations of NASA's next Orion flight test in 2018 will be explored in the full manuscript.

Horvath, Thomas J.↗
NASA NTRS2015

Conformal Ablative Thermal Protection Systems (CA-TPS) for Venus and Saturn Backshells

The new conformal ablator C-PICA, which was developed under STMD GCD, is an optimal candidate for use on the backshells for high velocity entry vehicles at both Venus and Saturn. The material has been tested at heat fluxes up to 400 Wcm2 in shear and over 1800 Wcm2 and 1.5 atm in stagnation with good results. C-PICA has similar density to PICA, but shows half the thermal penetration and similar recession at the same conditions, allowing for a lighter weight TPS to be flown. This poster for VEXAG will show the progress made in the development of the material and why it should be considered for use.

Conformal Ablative↗
DOE OSTI2024

Femto-second Laser’s Enabling New Length Scale Fabrications for Rapid Post Irradiation Examination of Materials: Concluding LDRD Project Poster

Mechanical testing campaigns are required to qualify materials for advanced reactor conditions, yet economical and safety limitations restrict the number of standardized mechanical tests that can be performed. Reducing the size of the sample is one approach to addressing these challenges and to accelerating testing. Previous research has shown that smaller mechanical test samples produce higher yield and ultimate stress values compared to values measured from standard sample sizes: the “smaller is stronger” effect. Specimens used in accelerated material testing campaigns must reflect bulk material performance to enable engineering scale material property measurement. The objective of this research project was to determine if engineering scale mechanical behavior—the yield stress—could be measured with micro-tensile test samples smaller than traditional standard testing geometries. The relationship between yield stress and sample size was explored with two different nuclear-relevant structural materials: Zircaloy-4 and tungsten. Mechanical testing of both metals demonstrated decreasing yield stress values with increasing sample gauge size across three different sizes. Yield stress values from the largest gauge size, fabricated with a femto-second laser ablation system, approach bulk material yield stress values reported in published literature. Preliminary analysis of the tungsten samples indicates the yield stress value depends on the grain characteristics within the gauge section, in addition to the gauge size. Accompanying modeling efforts, including response surface generation and crystal plasticity approaches, further demonstrated that the size of the sample gauge section alone cannot explain the change in yield stress values.

36 MATERIALS SCIENCE↗
NASA NTRS2019

Thermal Protection System Technology Maturation and Sustainment in Support of In-situ Science Missions: HEEET and PICA

Among the challenges faced by the Entry Descent and Landing (EDL) community have been: the lack of a matured forebody heatshield thermal protection system (TPS) capable of meeting the demanding entry environments for the high priority in-situ science missions identified in the decadal survey at Venus, Saturn and the Ice Giants, and the continued sustainment of thermal protection systems/materials. In response to the identified shortfall in TPS technologies capable of extreme entry environments NASA's Space Technology Mission Directorate (STMD) and Science Mission Directorate (SMD) initiated the Heatshield for Extreme Entry Environment Technology (HEEET) project which has matured a 3D-Woven TPS to Technology Readiness Level 6 and which is ready for infusion into these high priority missions. During the development of HEEET long term sustainability was a key consideration. However existing TPS also continue to face sustainability issues. Phenolic Impregnated Carbon Ablator (PICA) has been/is being utilized by many SMD Missions (Stardust, Mars Science Laboratory, OSIRIS-Rex, Mars 2020, Dragonfly) and is under consideration for others including Mars Sample Return, so maintaining PICA for the long term is a priority for NASA. This presentation will discuss raw material sustainability challenges faced by PICA and the efforts by NASA to work with Fiber Materials Inc (FMI) to resolve these challenges with a more sustainable supply chain. In addition, NASA is working with FMI to increase the manufacturing scale for single piece PICA heatshields and to expand the aerothermal performance envelop maturing PICA for larger sized heatshield and more aggressive entry environments. This presentation will also identify challenges and limitations with these systems, particularly around understanding failure modes in these materials and systems and how understanding these may allow use of these systems in environments that are difficult to achieve in ground based testing.

Heatshield for Extreme Entry Environment Technolog↗
NASA NTRS2017

Fully Coupled Aero-Thermochemical-Elastic Simulations of an Eroding Graphite Nozzle

A multiphysics simulation capability has been developed that incorporates mutual interactions between aerodynamics, structural response from aero/thermal loading, ablation/pyrolysis, heating, and surface-to-surface radiation to perform high-fidelity, fully coupled aerothermoelastic ablation simulations, which to date had been unattainable. The multiphysics framework couples CHAR (a 3-D implicit charring ablator solver), Loci/CHEM (a computational fluid dynamics solver for high-speed chemically reacting flows), and Abaqus (a nonlinear structural dynamics solver) to create a fully coupled aerothermoelastic charring ablative solver. The solvers are tightly coupled in a fully integrated fashion to resolve the effects of the ablation pyrolysis and charring process and chemistry products upon the flow field, the changes in surface geometry due to recession upon the flow field, and thermal-structural analysis of the body from the induced aerodynamic heating from the flow field. The multiphysics framework was successfully demonstrated on a solid rocket motor graphite nozzle erosion application. Comparisons were made with available experimental data that measured the throat erosion during the motor firing. The erosion data is well characterized, as the test rig was equipped with a windowed nozzle section for real-time X-ray radiography diagnostics of the instantaneous throat variations for deducing the instantaneous erosion rates. The nozzle initially undergoes a nozzle contraction due to thermal expansion before ablation effects are able to widen the throat. A series of parameters studies were conducted using the coupled simulation capability to determine the sensitivity of the nozzle erosion to different parameters. The parameter studies included the shape of the nozzle throat (flat versus rounded), the material properties, the effect of the choice of turbulence model, and the inclusion or exclusion of the mechanical thermal expansion. Overall, the predicted results match the experiment very well, and the predictions were able to bound the data within acceptable limits.

Blades, E. L.↗
NASA NTRS1972

Refurbishment cost study of the thermal protection system of a space shuttle vehicle. Phase 2: Supplement

The labor costs and techniques associated with the maintenance of a bonded-on ablator thermal protection system (TPS) concept, suitable for Space Shuttle application are examined. The baseline approach to TPS attachment involves bonding reusable surface insulation (RSI) and/or ablators to the structural skin of the vehicle. The RSI and/or ablators in the form of either flat or contoured panels can be bonded to the skin of the primary structure directly or by way of an intermediate silicone foam rubber pad. The use of foam rubber pads permits the use of buckling skins and protruding heat rivets on the primary structure, minimizing structural weight and fabrication costs. In the case of the RSI, the foam rubber pad serves as a required strain isolator. For purpose of comparison, test data were obtained for an installation with and without the use of a strain isolator. The refurbishment aspects of a bonded-on RSI concept (without a strain isolator) were examined experimentally along with several externally removable panel concepts employing both ablator and RSI TPS. The various concepts are compared.

Haas, D. W.↗