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Impact Testing for Materials Science at NASA - MSFC

The Impact Testing Facility (ITF) at NASA - Marshall Space Flight Center is host to different types of guns used to study the effects of high velocity impacts. The testing facility has been and continues to be utilized for all NASA missions where impact testing is essential. The Facility has also performed tests for the Department of Defense, other corporations, as well as universities across the nation. Current capabilities provided by Marshall include ballistic guns, light gas guns, exploding wire gun, and the Hydrometeor Impact Gun. A new plasma gun has also been developed which would be able to propel particles at velocities of 20km/s. This report includes some of the guns used for impact testing at NASA Marshall and their capabilities.

Sikapizye, Mitch↗

Marshall Space Flight Center's Impact Testing Facility Capabilities

Marshall Space Flight Center's (MSFC) Impact Testing Facility (ITF) serves as an important installation for space and missile related materials science research. The ITF was established and began its research in spacecraft debris shielding in the early 1960% then played a major role in the International Space Station debris shield development. As NASA became more interested in launch debris and in-flight impact concerns, the ITF grew to include research in a variety of impact genres. Collaborative partnerships with the DoD led to a wider range of impact capabilities being relocated to MSFC as a result of the closure of Particle Impact Facilities in Santa Barbara, California. The Particle Impact Facility had a 30 year history in providing evaluations of aerospace materials and components during flights through rain, ice, and solid particle environments at subsonic through hypersonic velocities. The facility's unique capabilities were deemed a "National Asset" by the DoD. The ITF now has capabilities including environmental, ballistic, and hypervelocity impact testing utilizing an array of air, powder, and two-stage light gas guns to accommodate a variety of projectile and target types and sizes. Relocated test equipment was dated and in need of upgrade. Numerous upgrades including new instrumentation, triggering circuitry, high speed photography, and optimized sabot designs have been implemented. Other recent research has included rain drop demise characterization tests to obtain data for inclusion in on-going model development. Future ITF improvements will be focused on continued instrumentation and performance enhancements. These enhancements will allow further, more in-depth, characterization of rain drop demise characterization and evaluation of ice crystal impact. Performance enhancements also include increasing the upper velocity limit of the current environmental guns to allow direct environmental simulation for missile components. The current and proposed ITF capabilities range from rain to micrometeoroids allowing the widest test parameter range possible for materials investigations in support of space, atmospheric, and ground environments. These test capabilities including hydrometeor, single/multi-particle, ballistic gas grins, exploding wire gun, and light gas guns combined with Smooth Particle Hydrodynamics Code (SPHC) simulations represent the widest range of impact test capabilities in the country.

Evans, Steve↗

NASA Marshall Impact Testing Facility Capabilities Applicable to Lunar Dust Work

The Impact Testing Facility at Marshall Space Flight Center has several guns that would be of use in studying impact phenomena with respect to lunar dust. These include both ballistic guns, using compressed gas and powder charges, and hypervelocity guns, either light gas guns or an exploding wire gun. In addition, a plasma drag accelerator expected to reach 20 km/s for small particles is under development. Velocity determination and impact event recording are done using ultra-high-speed cameras. Simulation analysis is also available using the SPHC hydrocode.

Evans, Steven W.↗

Preliminary investigations into UHCRE thermal control materials

An overview is given of the initial work which has been done in the European Space Research and Technology Center (ESTEC) Materials and Processes Division to evaluate the effect of space environment on the thermal blankets of the Ultra-Heavy Cosmic Ray Nuclei Experiment (UHCRE). Also, an account is given of the simulation of the impacts of micrometeoroids and space debris in a spare flight thermal blanket by means of plasma gun and light gas gun acceleration facilities.

Levadou, Francois↗

A Technique for Obtaining Hypervelocity Impact Data by using the Relative Velocities of Two Projectiles

A facility has been developed and put into operation to determine the feasibility of obtaining hypervelocity impact data by using the relative velocities of two projectiles. The facility utilizes the technique of firing a target toward an oncoming high-velocity projectile so that the impact velocity is equal to the sum of the projectile velocity and the target velocity. A 37-millimeter powder gun is utilized to accelerate the targets, and a specially designed 22-caliber light-gas gun accelerates the impacting projectiles. The light-gas gun is operated by detonating an explosive charge which permits it to be synchronized with the firing of the 37-millimeter gun. Impact velocities as great as 21,850 ft/sec have been obtained during development of the facility. After the oncoming projectiles impact the targets fired from the 37-millimeter gun, these targets are recovered by allowing them to impact into Celotex and soft wooden blocks. The craters formed in the targets then can be observed and measured. The results of several preliminary firings of the facility are included in this report.

Kinard, William H.↗

Ways to Increase Launch Velocities of 2-Stage Gas Guns

The amount of space debris is rapidly increasing and the debris is distributed over a wide variety of orbits. Satellites, manned space vehicles and space stations will have to pay increasing attention to the dangers of impacts with space debris. Various armoring techniques (i.e., double or triple layer armor) will have to tested extensively to determine the most effective armor per unit weight. Intersecting near-earth orbits can lead to impact velocities up to 15 km/sec. Conventional two-stage light gas guns can launch intact, controlled-shape projectiles with a density of 1.2 gm/cc and length- to-diameter ratios of 0.5-1.0 at velocities up to 8-9 km/sec. Higher velocities (10-11 km/sec) can be obtained' for very light projectiles. The higher launch velocities tend to be very severe on the high pressure coupling and barrel of the gun and lead to short component lifetimes. Clearly, the ability to raise the launch velocity of a gun (for reasonably massive projectile shapes) from 8-9 km/sec to 11-13 km/sec (or higher), without reduction of component lifetimes, would have significant benefits. This would allow much better simulation of the higher velocity debris impacts as well as better simulation of high speed re-entry into planetary atmospheres. Several techniques for increasing the launcher muzzle velocity above 8-9 km/sec have been studied using CFD simulations and appear to offer the potential for significant gains. The first technique is to use multiple compressions, instead of a single compression, in the pump tube of the light gas gun. In a sense, this is a kind of pre-heating of the gas in the pump tube; other types of pre-heating have yielded disappointing results in the past. The dynamics of the multiple compression pump tube is very different, however, from the earlier techniques, where the pump tube was typically heated ohmically before the gun 2 cycle was started. In this paper, we present CFD calculations that show that significant increases in muzzle velocity can be obtained with multiple compressions in the pump tube. With a conventional two-stage gun, an important limitation to obtaining higher velocities is friction and heat transfer to the barrel, which typically has a length- to- diameter ratio of 200-400. These viscous losses greatly reduce the effectiveness of the regions of the barrel far removed from the second stage breech. We have studied computationally the effect of adding an additional breech (or breeches) along the barrel to reduce these viscous losses. Velocity increases from 6.5 to 7.2 km/sec have been obtained using the main breech and one additional breech. In these results, both breeches were operated with hydrogen, heated electrothermally. We have also studied a gun geometry where the main breech is operated in the conventional manner, using piston compression. The additional breech is operated either with electrothermal heating or heating by using a high explosive charge in a novel geometry. The latter option provides very effective compression, heating and acceleration of the hydrogen working gas and is fully reusable. Calculations are presented which show that very substantial increases in muzzle velocity can be obtained this way, without overstressing the projectile or the 'gun. The third technique studied is to add a section of ram accelerator tube after the barrel to further accelerate the projectile. The ram accelerator used here is not the conventional premixed gas ram accelerator, but a new technique using high explosive as the energy source and pure hydrogen as the working gas in a geometry which can be made fully reusable. Preliminary results with this new rain accelerator geometry were presented and showed that stable ram accelerator drive can be established. Herein, detailed calculations axe presented which show that substantial velocity increases can be obtained using this ram accelerator technique in tandem with a conventional light gas gun.

Bogdanoff, David W.↗

Intact capture of hypervelocity particles on Shuttle

The capability for capturing micrometeoroid analogs intact through laboratory simulations in passive underdense media offers a valuable tool for cosmic dust research. However, no amount of laboratory simulations can replace actual space experiments due to the technical inability to launch high fidelity analogs of micrometeoroids in ground laboratories and then reliably simulating high hypervelocities (greater than 7 km/s). Fluffy composite micrometeoroid analogs tend to break up and have not survived laboratory launches at beyond 4 km/s, however, a new technique of launching cluster analogs was developed for the two-stage light-gas gun at NASA Ames Vertical Gun Range. Plasma drag or electrostatic accelerators may be able to achieve higher speeds than two-stage light-gas guns but only with very limited projectile compositions and may result in severe projectile deformation. Consequently, a space demonstration of intact capture was sought since 1983. Initial results from our STS-47 flight, which carried the first Shuttle Sample Return Experiment (SRE) with silica aerogel capture media, are reported.

Tsou, P.↗

Capabilities of the Impact Testing Facility at Marshall Space Flight Center

The test and analysis capabilities of the Impact Testing Facility at NASA's Marshall Space Flight Center are described. Nine different gun systems accommodate a wide range of projectile and target sizes and shapes at velocities from subsonic through hypersonic, to accomplish a broad range of ballistic and hypervelocity impact tests. These gun systems include ballistic and microballistic gas and powder guns, a two-stage light gas gun, and specialty guns for weather encounter studies. The ITF "rain gun" is the only hydrometeor impact gun known to be in existence in the United States that can provide single impact performance data with known raindrop sizes. Simulation of high velocity impact is available using the Smooth Particle Hydrodynamic Code. The Impact Testing Facility provides testing, custom test configuration design and fabrication, and analytical services for NASA, the Department of Defense, academic institutions, international space agencies, and private industry in a secure facility located at Marshall Space Flight Center, on the US Army's Redstone Arsenal in Huntsville, Alabama. This facility performs tests that are subject to International Traffic in Arms Regulations (ITAR) and DoD secret classified restrictions as well as proprietary and unrestricted tests for civil space agencies, academic institutions, and commercial aerospace and defense companies and their suppliers.

Finchum, Andy↗

Shock compression of crystalline TeO 2 to the high-pressure fluid regime: Insights from ab initio molecular dynamics simulations

The shock response of fully-dense and porous crystalline tellurium dioxide (TeO 2 ⁠) to the high-pressure and high-temperature fluid regime was investigated within the framework of density functional theory with Mermin’s generalization to finite temperatures. The principal and porous shock Hugoniot curves were predicted from canonical ab initio molecular dynamics (AIMD) simulations, with the phase space sampled along isotherms up to 80 000 K, for densities ranging from ρ = 3 to 17 g/cm 3 . The polymorphs investigated are α-TeO 2 paratellurite (⁠P4 1 2 1 2), TeO 2 cotunnite (⁠Pnma⁠), and TeO 2 post-cotunnite (⁠P2 1 /m⁠). Based on the discontinuity found in the calculated U s – u p slope of TeO 2 post-cotunnite at a shock velocity of U s ≃ 8.35km/s and a particle velocity of u p ≃ 3.64 km/s, the shock melting temperature and pressure are predicted to be ≃ 6500 K and ≃ 170 GPa. Results from the AIMD simulations are in line with the static compression data of TeO 2 paratellurite and cotunnite, and with the recent shock Hugoniot data for single-crystal α- TeO 2 for pressures up to 85 GPa, obtained using the inclined-mirror method and the velocity interferometer system for any reflector combined with powder gun and two-stage light-gas gun.

74 ATOMIC AND MOLECULAR PHYSICS↗

Recent Upgrades for the NASA Ames Vertical Gun Range

Recent upgrades to the performance capabilities of the NASA Ames Vertical Gun Range(AVGR) are presented. Upgrades include: the successful implementation of a fast-acting, gun gases suppression valve to minimize target contamination and perturbations to both the target and ejecta; powder gun and light-gas gun operational parameter adjustments to provide clean, low speed test conditions; a liquid nitrogen-based system and methodology for chilling targets and/or other impact chamber situated equipment; and imaging system capabilities enhancements to enable observing 50 micrometer particles traveling at 2 km/s. Many of these performance improvements were motivated by AVGR customer requirements for very clean shot conditions at speeds below 1.9 km/s and to provide testing in support of proposed NASA missions to Enceladus and 16-Psyche.

AVGR↗

The electrothermal ramjet

An electrothermal ramjet configuration is examined as a possible alternative to rail guns and mass drivers for high acceleration launch missions. For a specific mission (earth escape) the idealized performance of the electrothermal ramjet, the electrothermal rocket and the electromagnetic acceleration system are compared. This comparison indicates that the gross performance of the ramjet compares favorably with that of the ideal electromagnetic acceleration system. A specific configuration for the ramjet is chosen and models for the dynamics, thermodynamics and fluid mechanics are presented. Results of calculations for a typical supersonic launch cycle suggest that pressure, temperature and power demand profiles associated with ramjet operation should be reasonable. A light gas gun is proposed to accelerate the vehicle to the critical velocity where efficient ramjet operation can begin. The theoretical performance of the ramjet is also shown to be substantially better than that of the light gas gun at high velocities.

Wilbur, P. J.↗

Performance of Whipple Shields at Impact Velocities above 9 km/s

Whipple shields were first proposed as a means of protecting spacecraft from the impact of micrometeoroids in 1947 [1] and are currently in use as micrometeoroid and orbital debris shields on modern spacecraft. In the intervening years, the function of the thin bumper used to shatter or melt threatening particles has been augmented and enhanced by the use of various types and configurations of intermediate layers of various materials. All shield designs serve to minimize the threat of a spall failure or perforation of the main wall of the spacecraft as a result of the impact of the fragments. With increasing use of Whipple shields, various ballistic limit equations (BLEs) for guiding the design and estimating the performance of shield systems have been developed. Perhaps the best known and most used are the "new" modified Cour-Palais (Christiansen) equations [2]. These equations address the three phases of impact: (1) ballistic (<3 km/s), where the projectile is moving too slowly to fragment and essentially penetrates as an intact projectile; (2) shatter (3 to 7 km/s), where the projectile fragments at impact and forms an expanding cloud of debris fragments; and (3) melt/vaporization (>7 km/s), where the projectile melts or vaporizes at impact. The performance of Whipple shields and the adequacy of the BLEs have been examined for the first two phases using the results of impact tests obtained from two-stage, light-gas gun test firings. Shield performance and the adequacy of the BLEs has not been evaluated in the melt/vaporization phase until now because of the limitations of launchers used to accelerate projectiles with controlled properties to velocities above 7.5 km/s. A three-stage, light-gas gun, developed at the University of Dayton Research Institute (UDRI) [3], is capable of launching small, aluminum spheres to velocities above 9 km/s. This launcher was used to evaluate the ballistic performance of two Whipple shield systems, various thermal protection system materials, and other spacecraft-related materials to the impact of 1.6-mm- to 2.6-mm-diameter, 2017-T4 aluminum spheres at impact velocities ranging from 8.91 km/s to 9.28 km/s. Test results, details of the shield systems, and nominal ballistic limits for the two Whipple shields are shown in Figures 1 and 2.

Christiansen, Eric L.↗

Dynamic compression of TiO 2 to 221 GPa

The high-pressure dynamic response of titanium dioxide (TiO 2 ) is not only of interest because of its numerous industrial applications but also because of its structural similarities to silica (SiO 2 ). We performed plate impact experiments in a two-stage light gas gun, at peak stresses from 64 to 221 GPa to determine the TiO 2 response along the Hugoniot. The lower stress experiment at 64 GPa shows an elastic behavior followed by an elastic–plastic transition, whereas the high stress experiments above 64 GPa show a single wave structure. Previous shock studies have shown the presence of high-pressure phases (HPP) I (26 GPa) and HPP II (100 GPa); however, our data suggest that the HPP I phase is stable up to 150 GPa. Using a combination of data from our current study and our previous Z-data, we determine that TiO 2 likely melts on the Hugoniot at 157 GPa. Furthermore, our data confirm that TiO 2 is not highly incompressible as shown by a previous study.

36 MATERIALS SCIENCE↗

Shock compression and adiabatic release of a titaniferous mare basalt

A report is presented regarding the dynamic properties of a rock indigenous to the mare basins of the moon. The reported data were obtained in a study of sample 70215, a very titanium-rich basalt (58% pyroxene, 18% ilmenite, 15% plagioclase, 6% olivine, and 3% quartz by weight). This rock is probably representative of a class of the earliest mare-filling extrusive rocks which are exposed on the present lunar surface. Two series of experiments were performed. One set of experiments involved the measuring of Hugoniot and release adiabats to 15.7 GPa with a propellant gun apparatus. In the second set of experiments, a light-gas gun was employed to yield Hugoniot data at about 120 GPa and release states at about 90 GPa. Lunar basalt 70215 appears to be among the densest rocks in the present lunar sample collection, having a crystal density of 3.38 g/cu cm and a porosity of about 1.3%. The results of the experiments have important implications for both the degree of shock metamorphism expected for impact processes and the extent of ejecta transport on mare surfaces with high-titanium basalt composition.

Ahrens, T. J.↗

Reduction of Gun Erosion and Correlation of Gun Erosion Measurements

Gun barrel erosion is serious problem with two-stage light gas guns. Excessive barrel erosion can lead to poor or failed launches and frequent barrel changes, with the corresponding down time. Also, excessive barrel erosion can limit the maximum velocity obtainable by loading down the hydrogen working gas with eroded barrel material. Guided by a CFD code, the operating conditions of the Ames 0.5-inch gun were modified to reduce barrel erosion. The changes implemented included: (1) reduction in the piston mass, powder mass and hydrogen fill pressure; and (2) reduction in pump tube volume, while maintaining hydrogen mass. The latter change was found, in particular, to greatly reduce barrel erosion. For muzzle velocity ranges of 6.1 - 6.9 km/sec, the barrel erosion was reduced by a factor of 10. Even for the higher muzzle velocity range of 7.0 - 8.2 km/sec, the barrel erosion was reduced by a factor of 4. Gun erosion data from the Ames 0.5-inch, 1.0-inch, and 1.5-inch guns operated over a wide variety of launch conditions was examined and it was found that this data could be correlated using four different parameters: normalized powder charge energy, normalized hydrogen energy density, normalized pump tube volume and barrel diameter. The development of the correlation and the steps used to collapse the experimental data are presented. Over a certain parameter range in the correlation developed, the barrel erosion per shot is found to increase very rapidly. The correlation should prove useful in the selection of gun operating conditions and the design of new guns. Representative shapes of eroded gun barrels are also presented.

Bogdanoff, Dave↗

Hypervelocity Impact Testing of Nickel Hydrogen Battery Cells

Nickel-Hydrogen (Ni/H2) battery cells have been used on several satellites and are planned for use on the International Space Station. In January 1992, the NASA Lewis Research Center (LeRC) conducted hypervelocity impact testing on Ni/H2 cells to characterize their failure modes. The cell's outer construction was a 24 mil-thick Inconel 718 pressure vessel. A sheet of 1.27 cm thick honeycomb was placed in front of the battery cells during testing to simulate the on-orbit box enclosure. Testing was conducted at the NASA White Sands Test Facility (WSTF). The hypervelocity gun used was a 7.6 mm (0.30 caliber) two-stage light gas gun. Test were performed at speeds of 3, 6, and 7 km/sec using aluminum 2017 spherical particles of either 4.8 or 6.4 mm diameter as the projectile. The battery cells were electrically charged to about 75 percent of capacity, then back-filled with hydrogen gas to 900 psi simulating the full charge condition. High speed film at 10,000 frames/sec was taken of the impacts. Impacts in the dome area (top) and the electrode area (middle) of the battery cells were investigated. Five tests on battery cells were performed. The results revealed that in all of the test conditions investigated, the battery cells simply vented their hydrogen gas and some electrolyte, but did not burst or generate any large debris fragments.

Frate, David T.↗

Study of solid molecular deuterium D 2 growth under gas pressure

The injection of high-speed cryogenic pellets made of frozen hydrogen-isotopes, represents to date the most effective method to fuel magnetically confined thermonuclear fusion plasmas. Additionally, the injection of very large pellets composed of cryogenic solid of some suitable impurity (typically a noble-gas such as H 2 , Ne, or H 2 /Ne, D 2 /Ne mixtures), shattered in relatively small fragments just before entering the plasma, seems to be the most promising method to reduce the damage risks for the plasma-facing components in case of a plasma disruption. This technology, known as "Shattered Pellet Injection" (SPI), allows to spread out the plasma energy and mitigate possible damage to the in-vessel components, as well as to densify the plasma to suppress the formation of runaway electrons, and/or dissipate their energy. Several techniques to produce and launch cryogenic pellets have been investigated in the past decades. "Pipe gun" injectors are reliable and relatively simple devices are still commonly used today. They make use of single- or two-stage pneumatic light-gas guns to accelerate the pellet at high speeds. In these injectors, the cryogenic pellets are formed “ in situ ” (i.e., inside the launching barrel), by de-sublimating them directly from the gas phase, i.e., at temperatures and pressures below those of the triple point. The simplest case is pure deuterium pellets ($\mathcal{T}$ < 18.7 K, $\mathcal{P}$ < 171.3 hPa). The production of good quality solid deuterium, capable of withstanding the mechanical stress during the acceleration of the pellets, is a key issue. To this end the phase transition of deuterium from gas to solid (and vice versa) is modeled with extensive molecular-dynamics (MD) simulations. Furthermore, the solid growth from the gas phase is simulated in an ample range of temperatures and pressures, to find the best compromise between growth velocity and mechanical properties of the resulting solid system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗