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Code TS: Entry Systems and Technology Division

The TS division (Entry Systems and Technology Division) includes people who 1) Help design spacecraft for different exploration missions; 2) Figure out how hot the environments around a spacecraft will get; 3) Invent new materials that can protect the spacecraft; 4) Figure out how those materials will behave on a spacecraft and how thick they need to be; 5) Plan and perform tests on those materials and spacecraft designs to prove they will fly successfully; and 6) Help get those spacecraft ready to launch. This presentation will describe a little bit about all 6 areas.

Code TS

Challenges and Opportunities for Ensuring Entry System Technology Readiness for Ice Giants Probe Missions

The Ice Giants represent a distinct class of planets within our solar system, and appear to be similar to most exoplanets that have been detected thus far. Exploring Ice Giants in our Solar System would allow us to better understand their formation and evolution processes, and thus help establish scientific links to exoplanets. In situ exploration using probes similar to Galileo, along with an orbiter or a relay spacecraft, will require entry followed by deployment of the descent probe containing science instruments into Uranus or Neptune atmosphere. The challenge is not in the deployment of the probe, but in the atmospheric entry prior to deployment. The entry system has to have a capable, robust and efficient ablative thermal protection system (TPS) designed to protect the descent probe from the thermal and mechanical entry loads. Although entries into Ice Giants may not be as demanding as the Galileo entry at Jupiter, the entry environments will be more severe than environments for Mars, Sample Return missions, and Venus, and will therefore require robust TPS. While Galileo Probe’s success, nearly 25 years ago, should give us confidence, the recession data from the Galileo entry informs us that the entry environment was under-predicted and the design thickness was barely adequate. The lesson learned from the Galileo probe for future Ice Giant missions will require us to be cautious and demand a more robust design. The TPS technology used on the Galileo entry system no longer exists due to atrophy of manufacturing processes. Instead of attempting to revive Galileo-legacy TPS technology, NASA invested in a new and innovative TPS called HEEET (Heat-shield for Extreme Entry Environment Technology). HEEET has been matured, and is now ready to support future missions not only to the Ice Giants but also for Venus, high-speed sample return, and Saturn probe missions. This lead talk, intended for the technology section of the workshop, will cover entry, descent, and deployment (EDD), with an emphasis on entry. A brief history of the TPS challenges for extreme entry missions will be given, along with a quick overview of the concept of operations for EDD. The development and maturation of HEEET system capability will be described. Data gathered in ground-test facilities in the US will be highlighted to show that the technology is mature and ready for Ice Giant missions. All thermal protection systems carry some risk as a result of ground test limitations and Ice Giant missions present some unique challenges. These challenges are not only technical, but also due to limitations in the currently established manufacturing and integration. In addition, the concerns that arise due to the potential for atrophy for future Ice Giant missions a decade or more from now will be analyzed. Plausible avenues for mitigation will be presented. There are two planned companion presentations by Dr. Prabhu and Dr. Hwang that will dive deeper into the challenges and opportunities. This intended talk will set the stage for their presentations.

Venkatapathy, Ethiraj

Challenges and Opportunities For Ensuring Entry System Technology Readiness For Ice Giants Probe Missions

The Ice Giants represent a distinct class of planets within our solar system, and appear to be similar to most exoplanets that have been detected thus far. Exploring Ice Giants in our Solar System would allow us to better understand their formation and evolution processes, and thus help establish scientific links to exoplanets. In situ exploration using probes similar to Galileo, along with an orbiter or a relay spacecraft, will require entry followed by deployment of the descent probe containing science instruments into Uranus or Neptune atmosphere. The challenge is not in the deployment of the probe, but in the atmospheric entry prior to deployment. The entry system has to have a capable, robust and efficient ablative thermal protection system (TPS) designed to protect the descent probe from the thermal and mechanical entry loads. Although entries into Ice Giants may not be as demanding as the Galileo entry at Jupiter, the entry environments will be more severe than environments for Mars, Sample Return missions, and Venus, and will therefore require robust TPS. While Galileo Probe’s success, nearly 25 years ago, should give us confidence, the recession data from the Galileo entry informs us that the entry environment was under predicted and the design thickness was barely adequate. The lesson learned from Galileo probe for future Ice Giant missions will require us to be cautious and demand a more robust design. The TPS technology used on Galileo entry system no longer exists due to atrophy of manufacturing processes. Instead of attempting to revive Galileo-legacy TPS technology, NASA invested in a new and innovative TPS called HEEET (Heat-shield for Extreme Entry Environment Technology). HEEET has been matured, and is now ready to support future missions not only to the Ice Giants but also for Venus, high-speed sample return, and Saturn probe missions. This lead talk, intended for the technology section of the workshop, will cover entry, descent, and deployment (EDD), with an emphasis on entry. A brief history of the TPS challenges for extreme entry missions will be given along with a quick overview of the concept of operations for EDD. The development and maturation of HEEET system capability will be described. Data gathered in ground-test facilities in the US will be highlighted to show that the technology is mature and ready for Ice Giant missions. All thermal protection systems carry some risk as a result of ground test limitations and Ice Giant missions present some unique challenges. These challenges are not only technical, but also due to limitations in the currently established manufacturing and integration. In addition, the concerns that arise due to potential for atrophy for future Ice Giant mission a decade or more from now will be analyzed. Plausible avenues for mitigation will be presented. There are two companion planned presentations by Dr. Prabhu and Dr. Hwang will dive deeper in the challenges and opportunities. This intended talk will set the stage for their presentations.

Venkatapathy, Ethiraj

Validation and Sensitivity Analyses of Arc-Jet Performance of Woven Thermal Protection Entry Systems

Woven thermal protection materials for the Adaptable, Deployable, Entry and Placement Technology (ADEPT) entry system are simulated using a dual layer formalism in a finite volume implicit framework. The model developed and demonstrated here includes multi-dimensional and time-varying thermal response of the material to arc-jet test conditions. This work further demonstrates the sensitivities of the macro-scale thermal response to the through-thickness and in-plane conductivities of the carbon fabric, and to other experimental measurements such as cloth emissivity and thickness. The modeling can be extended to the ADEPT system that would encompass a single-piece woven heat shield configuration

Pratibha Raghunandan

Development of Inflatable Entry Systems Technologies

Achieving the objectives of NASA s Vision for Space Exploration will require the development of new technologies, which will in turn require higher fidelity modeling and analysis techniques, and innovative testing capabilities. Development of entry systems technologies can be especially difficult due to the lack of facilities and resources available to test these new technologies in mission relevant environments. This paper discusses the technology development process to bring inflatable aeroshell technology from Technology Readiness Level 2 (TRL-2) to TRL-7. This paper focuses mainly on two projects: Inflatable Reentry Vehicle Experiment (IRVE), and Inflatable Aeroshell and Thermal Protection System Development (IATD). The objectives of IRVE are to conduct an inflatable aeroshell flight test that demonstrates exoatmospheric deployment and inflation, reentry survivability and stability, and predictable drag performance. IATD will continue the development of the technology by conducting exploration specific trade studies and feeding forward those results into three more flight tests. Through an examination of these projects, and other potential projects, this paper discusses some of the risks, issues, and unexpected benefits associated with the development of inflatable entry systems technology.

Player, Charles J.

Investigation of Transonic Wake Dynamics for Mechanically Deployable Entry Systems

A numerical investigation of transonic flow around a mechanically deployable entry system being considered for a robotic mission to Venus has been performed, and preliminary results are reported. The flow around a conceptual representation of the vehicle geometry was simulated at discrete points along a ballistic trajectory using Detached Eddy Simulation (DES). The trajectory points selected span the low supersonic to transonic regimes with freestream Mach numbers from 1:5 to 0:8, and freestream Reynolds numbers (based on diameter) between 2:09 x 10(exp 6) and 2:93 x 10(exp 6). Additionally, the Mach 0:8 case was simulated at angles of attack between 0 and 5 . Static aerodynamic coefficients obtained from the data show qualitative agreement with data from 70deg sphere-cone wind tunnel tests performed for the Viking program. Finally, the effect of choices of models and numerical algorithms is addressed by comparing the DES results to those using a Reynolds Averaged Navier-Stokes (RANS) model, as well as to results using a more dissipative numerical scheme.

Stern, Eric

Mission Sizing and Trade Studies for Low Ballistic Coefficient Entry Systems to Venus

The U.S and the U.S.S.R. have sent seventeen successful atmospheric entry missions to Venus. Past missions to Venus have utilized rigid aeroshell systems for entry. This rigid aeroshell paradigm sets performance limitations since the size of the entry vehicle is constrained by the fairing diameter of the launch vehicle. This has limited ballistic coefficients (beta) to well above 100 kg/m2 for the entry vehicles. In order to maximize the science payload and minimize the Thermal Protection System (TPS) mass, these missions have entered at very steep entry flight path angles (gamma). Due to Venus thick atmosphere and the steep-gamma, high- conditions, these entry vehicles have been exposed to very high heat flux, very high pressures and extreme decelerations (upwards of 100 g's). Deployable aeroshells avoid the launch vehicle fairing diameter constraint by expanding to a larger diameter after the launch. Due to the potentially larger wetted area, deployable aeroshells achieve lower ballistic coefficients (well below 100 kg/m2), and if they are flown at shallower flight path angles, the entry vehicle can access trajectories with far lower decelerations (~50-60 g's), peak heat fluxes (~400 W/cm2) and peak pressures. The structural and TPS mass of the shallow-gamma, low-beta deployables are lower than their steep-gamma, high-beta rigid aeroshell counterparts at larger diameters, contributing to lower areal densities and potentially higher payload mass fractions. For example, at large diameters, deployables may attain aeroshell areal densities of 10 kg/m2 as opposed to 50 kg/m2 for rigid aeroshells. However, the low-beta, shallow-gamma paradigm also raises issues, such as the possibility of skip-out during entry. The shallow-gamma could also increase the landing footprint of the vehicle. Furthermore, the deployable entry systems may be flexible, so there could be fluid-structure interaction, especially in the high altitude, low-density regimes. The need for precision in guidance, navigation and control during entry also has to be better understood. This paper investigates some of the challenges facing the design of a shallow-gamma, low-beta entry system.

Dutta, Soumyo

An Aerodynamics Database for Aerocapture of a Conceptual Morphable Entry System at Mars

An aerodynamics database for aerocapture of a conceptual morphable entry system at Mars was developed. The vehicle is envisioned to employ deflections of its geometry to modulate angle of attack and sideslip angle for trajectory control. Modified Newtonian methods were used to compute hypersonic continuum aerodynamics. Direct simulation Monte Carlo calculations were carried out to compute data in the rarefied transitional regime. Free-molecular theory was used to compute values in the free-molecular regime. A bridging function method was then used to bridge data from all three flow regimes together and produce a database that can be used for future trajectory simulations to assess the vehicle’s performance. The vehicle was found to have the control authority in hypersonic continuum to effect an 18 deg change in the trim angle of attack using a 10 deg deflection of the pitching control surfaces. Similarly, a 6 deg change in the trim sideslip angle could be achieved with a 5 deg deflection of the yawing control surfaces. Different configurations of the vehicle were found to be statically stable in pitch and yaw in the continuum regime, but unstable in the rarefied and free-molecular regimes.

aerocapture

Current Investments in the NASA Entry Systems Modeling Project

This talk will provide an overview of investments in the Entry Systems Modeling project, along with some context of where the effort sits in the overall Space Technology EDL Portfolio. Technical highlights, particularly with referent to work on Ablation Modeling, will be given. Future directions will be discussed.

Aerothermodynamics

Earth Entry System Atmosphere Model Study

The Mars Sample Return Campaign has the ambitious goal of returning Mars samples back to Earth [1]. The Earth Entry System (EES), containing the samples, conducts entry, descent, and landing (EDL) on a direct Earth trajectory. During EDL, the EES traverses through many regions of Earth’s atmosphere before impacting the ground at Utah Test and Training Range (UTTR). This poster highlights preliminary results from a study that assessed the flight mechanics simulation sensitivity to atmosphere model settings and investigated the validity of current atmosphere models as compared to available atmospheric data measurements.

Rohan Deshmukh

Overview of Micrometeoroid and Orbital Debris Analysis Process for Mars Sample Return Earth Entry System

Introduction: Micrometeoroid and orbital debris (MMOD) risk analyses for the Mars Sample Return (MSR) Earth Entry System (EES) have been significantly more rigorous than previously flown missions because of its categorization as a Class V restricted return mission. This means the returned samples present significant concern for biogenic contamination. These analyses seek to determine if a micrometeoroid or orbital debris strike would result in loss of containment assurance and are summarized in the flowchart in Fig. 1. Methodology: The mission is considered in two MMOD phases: a pre-release phase where the EES is protected by a Micrometeoroid Protection System (MMPS) and a post-release phase called “free-flight” where the EES is exposed directly to the MMOD environment. These phases correspond to interplanetary cruise and imminent re-entry, respectively. To inform the MMPS design, a 30-shot high velocity impact testing (HVIT) series on candidate configurations at NASA White Sands Test Facility was completed in the summer of 2022. Sample post-shot images are shown in Fig 2 [1]. These data are used to baseline the MMPS design and to tune the hydrocode simulations. ALE3D, CTH, and SPHC are the hydrocodes that simulate physics of high-speed impacts [2]. Results generated with these populate a penetration depth versus energy space beyond the testable velocity regime of HVIT (~7 km/s). The penetration depth versus energy space data are used to define a critical projectile diameter function called a Ballistic Limit Equation (BLE), where the projectile “criticality” is determined by zone dependent failure criteria defined a-priori [3]. For example, the nose of the heatshield has a failure criterion of 50% TPS penetration, assigned because the landing loads are concentrated on that region and no substructure damage is permitted. The BLEs for each vehicle material zone are input into the BUMPER 3 code, along with the vehicle surface mesh and the corresponding space environment model, to calculate a probability of penetration or number of penetrations. The environment models, MEM3 for MM and ORDEM 3.2 for OD, simulate the meteoroid environment from 0.2 to 2 au based on the Grün flux equation, and the debris environment up to 40,000 km altitude from Earth surface, respectively [4,5]. Presentation Focus: The presentation or poster will present the results to-date focusing on the full risk analysis process flow seen in Fig. 1. Details on the derivation of the failure criteria will be discussed, along with HVIT results and how these influenced the MMPS configuration baseline decision. Further, results of hydrocode simulations will be presented and the tuning to HVIT outputs will be described. Finally, the strategies that direct the BLE formulation will be reviewed, specifically, for the EES elements that are most exposed to the MMOD environment.

mmod

A Plasma Aerocapture and Entry System for Manned Missions and Planetary Deep Space Orbiters

A rapid mission to Mars requires a large change in vehicle velocity upon arrival to establish a stable orbit. This demand is even greater for a Neptune science, requiring many kilometers per second of V. It is clear from past mission studies that a manned Mars mission and deep space planetary orbiters require aerobraking and aerocapture which use aerodynamic drag forces to slow the spacecraft. Aerocapture would enable long term studies of the outer planets and moons that would not be possible with existing braking methodologies. While the ability to utilize these atmospheres to slow down and capture spacecraft would dramatically reduce the cost, launch mass, and travel time, currently planned approaches require significant additional spacecraft mass and risk as the spacecraft must descend deep into the planetary atmosphere in order to produce significant drag on a relatively small aeroshell. The plasma based Magnetoshell being developed in this program holds the potential to perform the desired braking with significantly increased drag and control while dramatically reducing mass. Most importantly, this technology significantly lowers the risk involved with aerocapture thereby making manned planetary missions possible. The fundamental physics of the Magnetoshell is based on demonstrated experimental results. Successful implementation will dramatically decrease radiation exposures, mission risk, launch cost, and launch mass. Implementation of aerobraking by employing a solid deflector or aeroshell as a method for orbit insertion and circularization has been successfully demonstrated in the past, resulting in launch mass savings greater than 50%. In order to reduce the effect of frictional heating and dynamic pressure on the typically fragile aeroshell, or worse solar panels, the braking must be distributed over many orbital passes at a high altitude in the less dense regions of the atmosphere. It can thus take several months for a meter-scale, 1000 kg, aeroshell to execute the many elliptic orbital passes through the atmosphere to achieve the required V. This rather slow method of braking not only reduces frictional heating and dynamic forces, but also avoids unpredictable dynamic behavior due to turbulence, as well as unknown and seasonally variable atmospheric composition and temperature which has led to dangerous, mission-critical events. For exploration class missions such as DRA 5.0 aerocapture and Thermal Protection Systems (TPS) are proposed for breaking at Mars for cargo missions. Traditional aerocapture is considered too risky for manned missions. Even with the enormous mass savings that aerocapture allows, it still requires 80 tons of aeroshell and significantly increased launch mass and propellant. As will be shown, by using Magnetoshells for aerobraking, the DRA 5.0 mission will save 224 metric tons (MT) and greater than $2 B in launch costs. Beyond the dramatic savings for existing mission architectures, a low-mass, risk-free aerocapture system would allow much more rapid missions to Mars and deep space orbiters by allowing direct, faster trajectories. As will be shown, the plasma Magnetoshell Aerobraking, Aerocapture, and Entry System (AAES) not only reduces mass and cost while enabling significant new mission architectures, but also significantly reduces radiation exposures by decreasing trip times.

Manned Missions

Progress Toward Evaluating Roughness-Resolved Aerothermodynamic Simulations for the Mars Sample Return Earth Entry System

This work pursues the efficient Navier-Stokes simulation, using NASA’s standard LAURA and DPLR simulation tools, of the flowfield and convective heating resulting from the patterned-roughness surface of the Mars Sample Return (MSR) Earth Entry System (EES). This type of simulation has been infeasible for past NASA missions. However, for EES, the combination of a patterned roughness heatshield approximated with a sinusoidal pattern, the zero degrees angle of attack nominal flow, and the supersonic boundary layer edge Mach number, all combine to make these roughness resolved grid simulations feasible. The patterned roughness and zero degrees angle of attack nominal flow allow the simulation domain to be reduced to a thin axial flowfield slice that captures a minimum of single period of the roughness pattern. With a periodic boundary condition applied along the boundaries of this slice, simulation on the reduced domain is identical to the full domain but with significant cost saving. The supersonic boundary layer edge Mach number prevents the upstream influence, which allows the smooth stagnation region to be frozen. This freezing of the stagnation region flow is required because of the numerical instability resulting from the tight spacing of the grid in the axial direction as the stagnation point is approached. Applying the developed analysis approach to a peak heating EES case results in a roughness augmentation factor for the convective heating of 1.32, which agrees well with correlations that predict values between 1.30 and 1.37. Analysis approach developed in this work provides the framework for future studies of turbulence modeling impacts and the influence of an ablating surface.

Earth Entry System

Mechanical Testing of Soils from the South Range of the Utah Test and Training Range: Derivation of Soil Properties to Support the Earth Entry System Landing for Mars Sample Return

This report summarizes results from laboratory tests conducted by Applied Research Associates, Inc. (ARA) on soil samples collected from multiple sites within the South Range of the U.S. Air Force Utah Test and Training Range (UTTR). The goal of the laboratory tests was to establish soil constitutive properties and develop computational soil models enabling NASA to simulate impact landings of the Earth Entry System (EES) for the Mars Sample Return (MSR) mission. Test methods and results are presented describing the strength, compressibility, and stiffness of soils in the UTTR South Range including methods to incorporate the measured properties into Ansys LS-DYNAÒ constitutive material models for EES landing simulations.

Soil

3D Woven Mid-Density Carbon Phenolic (3MDCP) Full-Scale Heatshield Development for Mars Sample Return (MSR) Earth Entry System (EES)

The Mars Sample Return (MSR) mission will be returning samples of Martian soil to Earth. The samples will be returned in the Earth Entry System (EES). The EES capsule is protected by a new thermal protection system; the 3-Dimensionally Woven, Mid-Density, Carbon Phenolic (3MDCP) material which is derived from the Heatshield for Extreme Entry Environment Technology (HEEET). The baseline 3MDCP design is a single piece thermal protection system that avoids the manufacturing and certification challenges associated with a tiled configuration. A 3MDCP heatshield begins as a flat woven preform that is formed to the final heatshield shape and then infused with phenolic resin. A NASA Ames lead team, in collaboration with Spirit Textiles (formerly TEAM Inc.), Fiber Materials Inc. (FMI, a Spirit AeroSystems Company), and Kratos SRE, has been developing and demonstrating the processes to fabricate the 3MDCP heatshield and characterize the resulting properties. The process of forming the flat woven preform into the final heatshield shape, a sphere-cone geometry with a 52.5° cone angle, involves local but substantial movement of the yarns in the weave. This results in continuous fibers across the single piece heatshield, albeit with property variations between different regions of the heatshield. This presentation will provide a high-level status of 3MDCP development for the MSR EES heatshield. This will include an overview of the manufacturing processes with an emphasis on the impact of forming on fiber orientation, material properties, and performance. Results comparing preliminary formed and flat materials will be shown. Additionally, the presentation will layout the broader plan for property testing and tie-in to aerothermal performance.

Peter Edward Marshall