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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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NASA NTRS2018

Sustaining PICA for Future NASA Robotic Science Missions Including NF-4 and Discovery

Phenolic Impregnated Carbon Ablator (PICA), invented in the mid 1990's, is a low-density ablative thermal protection material proven capable of meeting sample return mission needs from the moon, asteroids, comets and other unrestricted class V destinations as well as for Mars. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. It is important that NASA maintain this thermal protection material capability and ensure its availability for future NASA use. The rayon based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years and a third substitution is now needed. The carbon precursor replacement challenge is twofold - the first involves finding a long-term replacement for the current rayon and the second is to assess its future availability periodically to ensure it is sustainable and be alerted if additional replacement efforts need to be initiated. This paper reviews current PICA sustainability activities to identify a rayon replacement and to establish that the capability of the new PICA derived from an alternative precursor is in family with previous versions.

Stackpoole, Mairead↗
NASA NTRS2018

Sustaining PICA for Future NASA Robotic Science Missions Including NF-4 and Discovery

Phenolic Impregnated Carbon Ablator (PICA), invented in the mid 1990's, is a low-density ablative thermal protection material proven capable of meeting sample return mission needs from the moon, asteroids, comets and other unrestricted class V destinations as well as for Mars. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. It is important that NASA maintain this thermal protection material capability and ensure its availability for future NASA use. The rayon based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years and a third substitution is now needed. The carbon precursor replacement challenge is twofold - the first involves finding a long-term replacement for the current rayon and the second is to assess its future availability periodically to ensure it is sustainable and be alerted if additional replacement efforts need to be initiated. This paper reviews current PICA sustainability activities to identify a rayon replacement and to establish that the capability of the new PICA derived from an alternative precursor is in family with previous versions.

Stackpoole, Mairead↗
NASA NTRSDate not supplied

The Material Response of PICA-NuSil to a Hypersonic Flow Environment

Phenolic Impregnated Carbon Ablator (PICA) is NASA’s baseline thermal protection system for missions to Mars. PICA is friable; therefore, NuSil ® CV-1144-0 is applied to the surface of flight hardware to mitigate the contamination of spacecraft sensors. NuSil is composed of a polysiloxane resin system that can transform into an oxidation-resistant coating upon heating. Therefore, a pathfinder campaign was conducted at the Hypersonic Materials Environmental Test System (HyMETS) at the NASA Langley Research Center to investigate the material response of instrumented sphere-cone models made from PICA coated with NuSil ® . Analysis of the post-test data is presented and suggests that NuSil ® impacts the material response of test articles subjected to oxidizing atmospheres, as evidenced by a reduction of the measured surface temperature and in-depth temperature response. Finally, a four-step ablation mechanism is proposed based on observations from high-speed video, optical emission spectroscopy, thermal analysis, and post-test surface characterization.

PICA PICA-NuSil Siloxane Silicone↗
NASA NTRS2016

PICA Status: New Frontiers and Discovery Missions

This is a set of slides for a 2 min talk at the OPAG meeting to update the community on the current status of PICA and future needs. The current vendor for manufacturing rayon for the heritage PICA has discontinued the production and as a result, the community needs to be aware of the efforts underway to consider options and demonstrate manufacturing as well as obtain properties and thermal response model of an alternate rayon based PICA that is sustainable for missions in support of upcoming New Frontiers and future Discovery Missions of Opportunity.

Thermal Protection System↗
NASA NTRSDate not supplied

Analysis of PICA-NuSil at the Hypersonic Materials Environmental Test System (HyMETS)

Phenolic Impregnated Carbon Ablator (PICA) gained heritage during the stardust mission and is the baseline material for missions to Mars. The phenolic phase of PICA is friable, and therefore the surface is treated with a siloxane resin (NuSil) to mitigate the shedding of particulate matter. Historically, material response models have not accounted for the presence of this coating. Therefore, a test campaign was executed at the Hypersonic Materials Environmental Test System (HyMETS) to investigate the performance of NuSil under multiple heating rates and gas composition. Sphere-cone models were instrumented with thermocouples to measure the in-depth temperature response, and surface temperatures were monitored with a pyrometer. Furthermore, emission spectrometers were used to collect spectra from species emitting at the surface of the test article and the post-shock stagnation region. Post-test analysis suggests that the coating decomposes according to multiple stages. Inspection of silicon emission data reveals a rapid rise and decline in intensity within the first couple of seconds of testing, which is attributed to pyrolysis of NuSil. Pyrolysis is followed by a stagnation in silicon emission and surface temperature which are attributed to the formation of a thin layer of oxidation-resistant silicon oxycarbide. Moreover, the presence of the silicon oxycarbide layer significantly reduces the in-depth thermal response when compared to the baseline material. Eventually, the silicon oxycarbide layer decomposes via high-temperature reactions, which expose the underlying char layer to a highly reactive flow.

PICA-NuSil↗
NASA NTRS2009

Validation of PICA Ablation and Thermal-Response Model at Low Heat Flux

Phenolic Impregnated Carbon Ablator (PICA) was the forebody heatshield material on the Stardust sample-return capsule and is also a primary candidate material for the Mars Science Lander (MSL), the Orion Crew Module, and the SpaceX Dragon vehicle. As part of the heatshield qualification for Orion, physical and thermal properties of virgin and charred PICA were measured, and an ablation and thermal response model was developed. We validated the model by comparing it with recession and temperature data from stagnation arcjet tests conducted over a wide range of stagnation heat flux of 107 to 1102 W/sq cm. The effect of orthotropic thermal conductivity was evident in the thermal response of the arcjet models. In general, model predictions compared well with the data; however, the uncertainty of the recession prediction was greatest for heat fluxes below 200 W/sq cm. More recent MSL testing focused on the low heat flux regime of 45 to 250 W/sq cm. The new results confirm the recession uncertainty, especially for pressures below 6 kPa. In this work we focus on improving the model predictions for MSL and Orion tests below 250 W/sq cm.

Milos, Frank S.↗
NASA NTRS2016

Characterization of Ablation Product Radiation Signatures of PICA and FiberForm

Emission spectroscopy measurements in the post-shock layer in front of low density ablative material samples of different shapes were obtained in the NASA Langley HYMETS arcjet facility. A horizontal line of measurement positions was imaged on the entrance slit of the spectrometer allowing detection of the entire stagnation line in front of the samples. The stagnation line measurements were used to compare the post-shock layer emission signatures in front of PICA and FiberForm. The emission signatures of H, NH, and OH are characteristic for pyrolysis gases and consequently were only observed in front of the PICA samples. CN and C were found in front of both materials and are mainly due to interactions of the carbon fibers with the plasma. In all tests with instrumented samples, the emission of Mn, Cr, and Ni was observed when the thermocouple temperatures reached or exceeded ~1,500 K, strongly indicating erosion of the molten thermocouple tips. Temperatures in the post-shock layer were estimated from comparing the CN band emission to spectral simulation. The resulting rotational and vibrational temperatures were on the order of 7,000 to 9,000 K and close to each other indicating a plasma condition close to equilibrium. In addition to the stagnation line configurations, off-axis lines of observation were investigated to gather information about spalled particles in the flow. From a comparison of measured continuum emission with simulated Planck radiation, average particle temperatures along the measured line of observation were determined for two cases. Particle temperatures between 3,500 and 2,000 K were found. A comprehensive investigation of the entire amount of data set is ongoing.

Winter, Michael↗
NASA NTRS2017

3D Material Response Analysis of PICA Pyrolysis Experiments

The PICA decomposition experiments of Bessire and Minton are investigated using 3D material response analysis. The steady thermoelectric equations have been added to the CHAR code to enable analysis of the Joule-heated experiments and the DAKOTA optimization code is used to define the voltage boundary condition that yields the experimentally observed temperature response. This analysis has identified a potential spatial non-uniformity in the PICA sample temperature driven by the cooled copper electrodes and thermal radiation from the surface of the test article (Figure 1). The non-uniformity leads to a variable heating rate throughout the sample volume that has an effect on the quantitative results of the experiment. Averaging the results of integrating a kinetic reaction mechanism with the heating rates seen across the sample volume yield a shift of peak species production to lower temperatures that is more significant for higher heating rates (Figure 2) when compared to integrating the same mechanism at the reported heating rate. The analysis supporting these conclusions will be presented along with a proposed analysis procedure that permits quantitative use of the existing data. Time permitting, a status on the in-development kinetic decomposition mechanism based on this data will be presented as well.

Oliver, A. Brandon↗
NASA NTRS2018

Remote Recession Measurements of Wire-Seeded PICA Samples in an Arc-Jet Flow

Various methods for remote recession sensing of PICA have been developed and several seeding methods have been tested. The most recent method involved seeding the ablator with wires fed to the sample from the backside with a defined amount of PICA left towards the upstream front of the sample. This seed method mimics the installation of in-depth thermocouples as they are frequently used in ground testing and flight. Arc-jet tests were conducted in the NASA Langley HYMETS facility at a heat flux of 320 W/sq.cm. The emission of the post-shock layer was observed in spectral resolution from the side along an optical axis perpendicular to the arc-jet flow and from the front, looking at the sample surface from an upstream position. Various metallic seed materials with different melting points were used. In addition to the emission spectroscopy measurements, the samples were monitored during the tests through pyrometry and videography. The time resolved response of the seeded material is described and compared to earlier tests with different seeding methods. The combination of seed materials was found to be critical for the selection of emission signatures characteristic for the material recession which can be isolated in the final emission spectra.

Winter, Michael↗
NASA NTRSDate not supplied

Analysis of PICA-NuSil at the Hypersonic Materials Environmental Test System (HyMETS)

Phenolic Impregnated Carbon Ablator (PICA) gained heritage during theStardust mission and is the baseline thermal protection system (TPS) material for missions to Mars. However, PICA is friable, so a thin layer of siloxane resin (NuSil) is applied to the surface of the heat shield to suppress the spread of particulate matter during cleanroom activities. Until recently, the thermochemical response of NuSil had not been accounted for in material response models. Therefore, a test campaign was executed at the Hypersonic Materials Environmental Test System (HyMETS) facility to investigate the material response of NuSil and provide crucial insight for model development. Finally, salient results from an experiment supported by the AsteroidThreat Assessment Project (ATAP) will be discussed, which probed the materialr esponse of the Tamdakht meteorite and notable analogs.

Brody K. Bessire↗
NASA NTRS2015

Pressure Venting Tests of Phenolic Impregnated Carbon Ablator (PICA)

A series of tests was devised to investigate the pressure venting behavior of one of the candidate ablators for the Orion capsule heat shield. Three different specimens of phenolic impregnated carbon ablator (PICA) were instrumented with internal pressure taps and subjected to rapid pressure changes from near vacuum to one atmosphere and simulated Orion ascent pressure histories. The specimens vented rapidly to ambient pressure and sustained no detectable damage during testing. Peak pressure differences through the thickness of a 3-inch-thick specimen were less than 1 psi during a simulated ascent pressure history.

Blosser, Max L.↗
NASA NTRS2017

3D Material Response Analysis of PICA Pyrolysis Experiments

Primarily interested in improving ablation modeling for use in inverse reconstruction of flight environments on ablative heat shields. Ablation model is essentially a component of the heat flux sensor, so model uncertainties lead to measurement uncertainties. Non-equilibrium processes have been known to be significant in low density ablators for a long time, but increased accuracy requirements of the reconstruction process necessitates incorporating this physical effect. Attempting to develop a pyrolysis model for implementation in material response based on the PICA data produced by Bessire and Minton. Pyrolysis gas species molar yields as a function of temperature and heating rate. Several problems encountered while trying to fit Arrhenius models to the data led to further investigation of the experimental setup.

Oliver, Brandon A.↗
NASA NTRSDate not supplied

High-Fidelity Simulations of HyMETS Arc-Jet Flows for PICA-N Modeling

Arc-jet testing is a fundamental tool in the screening of thermal protection systems under atmospheric entry conditions. In this work, high-fidelity computational fluid dynamics simulations coupled with machine learning methods for the Hypersonic Materials Environmental Test System arc-jet facility have been carried out. This effort improves the MEDLI-2 data reconstruction fidelity by understanding the impact of the NuSil coating over the PICA thermocouple plugs. Thermochemical non-equilibrium models are employed to simulate the flows inside the arc-jet nozzle and chamber and machine learning techniques are used to calibrate the arc-jet inflow conditions. The material response is simulated with the recession and in-depth numerical results compared to experimental measurements.

STMD↗
NASA NTRS2008

Multiscale Modeling of Ablation and Pyrolysis in PICA-Like materials

During atmospheric entry of planetary probes, the thermal protection system (TIPS) of the probe is exposed to high temperatures under low pressures. In these conditions, carbonous fibrous TIPS materials may undergo oxidation leading to mass loss and wall recession called ablation. This work aims to improve the understanding of material/environment interactions through a study of the coupling between oxygen transport in the Knudsen regime, heterogeneous oxidation of carbon, and surface recession. A 3D Random Walk Monte Carlo simulation tool is used for this study. The fibrous architecture of a model material, consisting of high porosity random array of carbon fibers, is numerically represented on a 3D Cartesian grid. Mass transport in the Knudsen regime from the boundary layer to the surface, and inside this porous material is simulated by random walk. A reaction probability is used to simulate the heterogeneous oxidation reaction. The surface recession of the fibers is followed by front tracking using a simplified marching cube approach. The output data of the simulations are ablation velocity and dynamic evolution of the material porosity. A parametric study is carried out to analyze the material behavior as a function of Knudsen number for the porous media (length of the mean free path compared to the mean pore diameter) and the intrinsic reactivity of the carbon fibers. The model is applied to Stardust mission reentry conditions and explains the unexpected behavior of the TIPS material that underwent mass loss in volume.

Lachaud, Jean↗