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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↗

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↗

Acoustic Emission Analysis of Shuttle Thermal Protection System

Acoustic emission (AE) signals generated from projectile impacts on reinforced and advanced carbon/carbon (RCC and ACC) panels, fired from a compressed-gas gun, identify the type and severity of damage sustained by the target. This type of testing is vital in providing the required "return to flight" (RTF) data needed to ensure continued and safe operation of NASA's Space Shuttle fleet. The gas gun at Kennedy Space Center is capable of propelling 12-inch by 3-inch cylinders of external tank (ET) foam at exit velocities exceeding 1,000 feet per second. Conventional AE analysis techniques require time domain processing of impulse data, along with amplitude distribution analysis. It is well known that identical source excitations can produce a wide range of AE signals amplitudes. In order to satisfy RTF goals, it is necessary to identify impact energy levels above and below damage thresholds. Spectral analysis techniques involving joint time frequency analysis (JTFA) are used to reinforce time domain AE analysis. JTFA analysis of the AE signals consists of short-time Fourier transforms (STFT) and the Huang-Hilbert transform (HHT). The HHT provides a very good measure of the instantaneous frequency of impulse events dominated by a single component. Identifying failure modes and cracking of fibers from flexural and/or extensional mode acoustic signals will help support in-flight as well as postflight impact analysis.

Lane, John↗

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.↗

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.↗

A dynamic study of fragmentation and energy loss during high velocity impact

Research conducted under this contract can be divided into two main areas: hypervelocity (in the range up to 7 km/s) and high velocity (less than 1 km/s). Work in the former was performed at NASA-MSFC using the Light Gas Gun Facility. The lower velocity studies were conducted at Auburn University using the ballistic gun. The emphasis of the project was on the hypervelocity phenomenon especially in the characterization of the debris cloud formed by the primary impact events. Special devices were made to determine the angular distributions of momentum and energy of the debris cloud as a function of impact conditions. After several iteration processes, it was decided to concentrate on the momentum effort. Prototype devices were designed, fabricated, and tested. These devices were based on the conservation of momentum. Distributions of the debris cloud formed were measured by determining the amount of momentum transferred from the debris cloud to strategically placed pendulum measurement devices. The motion of the pendula was monitored using itegrated opto-interrupters. The distribution of momentum in the debris cloud was found to be a strong function of the impact condition. Small projectiles at high velocities were observed to produce finely dispersed debris whereas large projectiles generated discrete particles in the debris. Results also show that the momentum in the forward direction was enhanced due to the impact. This phenomenon of momentum multiplication was also observed in other studies and in computer simulations. It was initially planned to determine the energy distribution using deformation energy in a rod with strain gauges. Results from preliminary studies show that this technique is acceptable but too tedious. A new technique was explored based on measuring the heating effect of the debris cloud using an IR camera. The feasibility and sensitivity was established at Auburn University. This type of energy distribution measurement method can easily be adapted to the gas gun facility at MSFC. The objective of the lower velocity studies at Auburn was to simulate the damage produced in advanced materials by the lower energy debris cloud.

Zee, Ralph H.↗

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↗

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↗

NASA Ames Arc Jets and Range, Capabilities for Planetary Entry

NASA is pursuing innovative technologies and concepts as part of America's Vision for Space Exploration. The rapidly emerging field of nanotechnology has led to new concepts for multipurpose shields to prevent catastrophic loss of vehicles and crew against the triple threats of aeroheating during atmospheric entry, radiation (Solar and galactic cosmic rays) and Micrometorid/Orbital Debris (MMOD) strikes. One proposed concept is the Thermal Radiation Impact Protection System (TRIPS) using carbon nanotubes, hydrogenated carbon nanotubes, and ceramic coatings as a multi-use TPS. The Thermophysics Facilities Branch of the Space Technology Division at NASA Ames Research Center provides testing services for the development and validation of the present and future concepts being developed by NASA and national and International research firms. The Branch operates two key facilities - the Range Complex and the Arc Jets. The Ranges include both the Ames Vertical Gun Range (AVGR) and the Hypervelocity Free Flight (HFF) gas guns best suited for MMOD investigations. Test coupons can be installed in the AVGR or HFF and subjected to particle impacts from glass or metal particles from micron to _ inch (6.35-mm) diameters and at velocities from 5 to 8 kilometers per second. The facility can record high-speed data on film and provide damage assessment for analysis by the Principle Investigator or Ames personnel. Damaged articles can be installed in the Arc Jet facility for further testing to quantify the effects of damage on the heat shield s performance upon entry into atmospheric environments.

Fretter, Ernest F.↗

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.↗

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.↗

Guns and High Gas Output Devices Panel: Introduction

A new panel known as the Guns and High Gas Output Panel was organized in 1999 under the auspices of the JANNAF Propellant and Characterization SubCommittee (PDCS). This is an introduction to our first meeting, purpose of the panel, and the scope of activities to be covered. The primary purpose of the panel is very simple: to provide a single focal point for interfacing Government Laboratories (Department of Defense and Department of Energy) and commercial industry researchers to share R&D activities and findings (i.e. facilitate the exchange of information) specifically aimed at gun-launched propulsion and high-gas output devices (gas generators and air bag inflators). Specific areas of interest included in the Panel's scope (and the Technical Data Base) are the following: (1) new propellant formulations and chemistry, (2) new ingredients, (3) ballistic effects of the new formulations and ingredients, (4) new processing methods unique to gun propellants, (5) thermochemistry of new ingredients, (6) unique physical and mechanical properties, (7) burning rates of new propellants and small scale closed bomb testing, (8) plasma effects on the propellant, and (9) unique safety and insensitive munitions properties.

Simmons, Ronald L.↗

Initiation of combustion in the thermally choked ram accelerator

The methodology for initiating stable combustion in a ram accelerator operating in the thermally choked mode is presented in this paper. The ram accelerator is a high velocity ramjet-in-tube projectile launcher whose principle of operation is similar to that of an airbreathing ramjet. The subcaliber projectile travels supersonically through a stationary tube filled with a premixed combustible gas mixture. In the thermally choked propulsion mode subsonic combustion takes place behind the base of the projectile and leads to thermal choking, which stabilizes a normal shock system on the projectile, thus producing forward thrust. Projectiles with masses in the 45-90 g range have been accelerated to velocities up to 2650 m/sec in a 38 mm bore, 16 m long accelerator tube. Operation of the ram accelerator is started by injecting the projectile into the accelerator tube at velocities in the 700 - 1300 m/sec range by means of a conventional gas gun. A specially designed obturator, which seals the bore of the gun during this initial acceleration, enters the ram accelerator together with the projectile. The interaction of the obturator with the propellant gas ignites the gas mixture and establishes stable combustion behind the projectile.

Bruckner, A. P.↗

The Ames Vertical Gun Range

The Ames Vertical Gun Range (AVGR) is a national facility for conducting laboratory- scale investigations of high-speed impact processes. It provides a set of light-gas, powder, and compressed gas guns capable of accelerating projectiles to speeds up to 7 km s(exp -1). The AVGR has a unique capability to vary the angle between the projectile-launch and gravity vectors between 0 and 90 deg. The target resides in a large chamber (diameter approximately 2.5 m) that can be held at vacuum or filled with an experiment-specific atmosphere. The chamber provides a number of viewing ports and feed-throughs for data, power, and fluids. Impacts are observed via high-speed digital cameras along with investigation-specific instrumentation, such as spectrometers. Use of the range is available via grant proposals through any Planetary Science Research Program element of the NASA Research Opportunities in Space and Earth Sciences (ROSES) calls. Exploratory experiments (one to two days) are additionally possible in order to develop a new proposal.

The chamber provides a number of viewing ports and↗

Meteor Crater: Energy of formation - Implications of centrifuge scaling

Recent work on explosive cratering has demonstrated the utility of performing subscale experiments on a geotechnic centrifuge to develop scaling rules for very large energy events. The present investigation is concerned with an extension of this technique to impact cratering. Experiments have been performed using a projectile gun mounted directly on the centrifuge rotor to launch projectiles into a suitable soil container undergoing centripetal accelerations in excess of 500 G. The pump tube of a two-stage light-gas gun was used to attain impact velocities of approximately 2 km/sec. The results of the experiments indicate that the energy of formation of any large impact crater depends upon the impact velocity. This dependence, shown for the case of Meteor Crater, is consistent with analogous results for the specific energy dependence of explosives and is expected to persist to impact velocities in excess of 25 km/sec.

Schmidt, R. M.↗

High-speed Imaging of Global Surface Temperature Distributions on Hypersonic Ballistic-Range Projectiles

The NASA-Ames ballistic range provides a unique capability for aerothermodynamic testing of configurations in hypersonic, real-gas, free-flight environments. The facility can closely simulate conditions at any point along practically any trajectory of interest experienced by a spacecraft entering an atmosphere. Sub-scale models of blunt atmospheric entry vehicles are accelerated by a two-stage light-gas gun to speeds as high as 20 times the speed of sound to fly ballistic trajectories through an 24 m long vacuum-rated test section. The test-section pressure (effective altitude), the launch velocity of the model (flight Mach number), and the test-section working gas (planetary atmosphere) are independently variable. The model travels at hypersonic speeds through a quiescent test gas, creating a strong bow-shock wave and real-gas effects that closely match conditions achieved during actual atmospheric entry. The challenge with ballistic range experiments is to obtain quantitative surface measurements from a model traveling at hypersonic speeds. The models are relatively small (less than 3.8 cm in diameter), which limits the spatial resolution possible with surface mounted sensors. Furthermore, since the model is in flight, surface-mounted sensors require some form of on-board telemetry, which must survive the massive acceleration loads experienced during launch (up to 500,000 gravities). Finally, the model and any on-board instrumentation will be destroyed at the terminal wall of the range. For these reasons, optical measurement techniques are the most practical means of acquiring data. High-speed thermal imaging has been employed in the Ames ballistic range to measure global surface temperature distributions and to visualize the onset of transition to turbulent-flow on the forward regions of hypersonic blunt bodies. Both visible wavelength and infrared high-speed cameras are in use. The visible wavelength cameras are intensified CCD imagers capable of integration times as short as 2 ns. The infrared camera uses an Indium Antimonide (InSb) sensor in the 3 to 5 micron band and is capable of integration times as short as 500 ns. The projectiles are imaged nearly head-on using expendable mirrors offset slightly from the flight path. The proposed paper will discuss the application of high-speed digital imaging systems in the NASA-Ames hypersonic ballistic range, and the challenges encountered when applying these systems. Example images of the thermal radiation from the blunt nose of projectiles flying at nearly 14 times the speed of sound will be given.

Wilder, Michael C.↗