Search NASA⌕ Search

SEARCH · Search NASA

Results for “Reusable TPS”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Aerocapture for manned Mars missions - Status and challenges

The current status for manned Mars missions and the associated challenges are summarized. Mission benefits are considered to increase with increasing Mars entry velocity. However, significant benefits accrue at moderate entry velocities between 7 and 8 km/sec, which is the realistically achievable range in view of g-limits and heating constraints. Blunt, low mass/drag coefficient (reference area) vehicles with L/Ds from 0.3 to 0.5 are found to be the preferred configurations, taking into account their adequate control authority and good payload packaging characteristics. The overall design characteristics of Mars aerocapture vehicles can be established with good confidence, using flight and ground test data and the state-of-the-art flow field analysis techniques. The principal challenges are identified as follows: to refine the knowledge of the Martian atmosphere in order to reduce design conservatism, to extend present stagnation region heating analyses to the entire vehicle forebody, and to develop reflective low-wall-catalycity TPS systems for enabling reusable vehicles.

Walberg, Gerald D.↗
NASA NTRSDate not supplied

Advanced TUFROC Thermal Protection System Evolution Under Re-entry like Conditions

Toughened Unipiece Fibrous Reinforced Oxidation-resistant Composite (TUFROC) and its successor, Advanced TUFROC, are state-of-the-art thermal protection systems (TPS) for high temperature reusable applications. Originally designed for use on the wing-leading edge of X-37B, TUFROC is an insulative tiled system consisting of a low-conductivity ceramic base, a carbonaceous cap, and multiple coatings for thermal performance. The improved Advanced TUFROC has demonstrated reusability up to 2900 °F and single use capabilities exceeding 3200 °F. This effort explores the evolution of Advanced TUFROC when exposed to re-entry like conditions via arc jet testing. Chemical reactions and constituent migration resulting from the aerothermal heating are known to occur and are studied in detail. Further, the interaction between the multiple constituents and layers will be discussed as this is believed to have a significant impact on the overall performance. Characterization includes structural analysis via optical microscopy, scanning electron microscopy and energy-dispersive x-ray spectroscopy.

Thermal protection system↗
NASA NTRS1998

Orbital Debris Impact Damage to Reusable Launch Vehicles

In an effort by the National Aeronautics and Space Administration (NASA), hypervelocity impact tests were performed on thermal protection systems (TPS) applied on the external surfaces of reusable launch vehicles (RLV) to determine the potential damage from orbital debris impacts. Three TPS types were tested, bonded to composite structures representing RLV fuel tank walls. The three heat shield materials tested were Alumina-Enhanced Thermal Barrier-12 (AETB-12), Flexible Reusable Surface Insulation (FRSI), and Advanced Flexible Reusable Surface Insulation (AFRSI). Using this test data, predictor equations were developed for the entry hole diameters in the three TPS materials, with correlation coefficients ranging from 0.69 to 0.86. Possible methods are proposed for approximating damage occurring at expected orbital impact velocities higher than tested, with references to other published work.

Robinson, Jennifer H.↗
NASA NTRS1972

Structural active cooling applications for the Space Shuttle.

Analytic and experimental studies have been conducted to evaluate a number of active cooling approaches to structural thermal protection for the Space Shuttle. The primary emphasis was directed toward the thermal protection system. Trade study results are presented for various heat shield material and TPS arrangements. Both metallic and reusable surface insulation (RSI) concepts were considered. Active systems heat sinks consisted of hydrogen, phase change materials, and expendable water. If consideration is given only to controlling the surface temperature, passive TPS was found to provide the most efficient system. Use of active cooling which incorporates some interior temperature control made the thermally less efficient RSI system more attractive.

Masek, R. V.↗
NASA NTRS2024

Advanced Lightweight TUFROC Thermal Protection System for Space Plane Applications

Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC) represents the state of the art in low-cost, reusable spacecraft Thermal Protection Systems (TPS) with high temperature capability and is flight proven on the USAF X-37B. The two-piece design takes advantage of a low-conductivity porous silica substrate combined with high-temperature-capable carbon cap and surface treatments. NASA has updated the chemical composition of the surface treatments resulting in improved high-heating capability and reusability. The new system, called Advanced TUFROC, experiences a lower surface temperature (by ~80 K) at identical aerothermal heating conditions compared to the original formulation, now called Standard TUFROC. The reduced heating is attributed to the lower catalytic efficiency of the new formulation, which results in reduced exothermic atom recombination rates at the surface. Multiple arc-jet test campaigns demonstrate that Advanced TUFROC has the ability to withstand long and repeated exposures at 1866 K or a shorter duration exposure at 1980 K without recession or damage to TPS. Furthermore, an improved arc-jet article design for assessing 3-dimensional flow over a wing leading edge has been developed and tested. This article allows for assessment of heating at a tile gap under flight-relevant conditions at significantly reduced article fabrication and arc-jet facility configuration costs compared to prior work.

TUFROC↗
NASA NTRS1981

Effect of load eccentricity and substructure deformation on ultimate strength of shuttle orbiter thermal protection system

The effect of load eccentricity and substructure deformation on the ultimate strength and stress displacement properties of the shuttle orbiter thermal protection system (TPS) was determined. The LI-900 Reusable Surface Insulation (RSI) tiles mounted on the .41 cm thick Strain Isolator Pad (SIP) were investigated. Substructure deformations reduce the ultimate strength of the SIP/tile TPS and increase the scatter in the ultimate strength data. Substructure deformations that occur unsymmetric to the tile can cause the tile to rotate when subjected to a uniform applied load. Load eccentricity reduces SIP/tile TPS ultimate strength and causes tile rotation.

Sawyer, J. W.↗
NASA NTRS1996

TPS Sizing for Access-to-Space Vehicles

A study was carried out to identify, develop, and benchmark simulation techniques needed for optimum thermal protection system (TPS) material selection and sizing for reusable launch vehicles. Fully viscous, chemically reacting, Navier-Stokes flow solutions over the Langley wing-body single stage to orbit (SSTO) configuration were generated and coupled with an in-depth conduction code. Results from the study provide detailed TPS heat shield materials selection and thickness sizing for the wing-body SSTO. These results are the first ever achieved through the use of a complete, trajectory based hypersonic, Navier-Stokes solution database. TPS designs were obtained for both laminar and turbulent entry trajectories using the Access-to-Space baseline materials such as tailorable advanced blanket insulation. The TPS design effects (materials selection and thickness) of coupling material characteristics to the aerothermal environment are illustrated. Finally, a sample validation case using the shuttle flight database is included.

Henline, William↗
NASA NTRS1975

Evaluation of coated columbium for thermal protection systems application

Coated columbium alloys were evaluated for thermal protection system (TPS) application in the maximum operating temperature range from 1370 to 1590 K. Evaluation of materials combinations, subsize panels, and single panel TPS led to the development of a full-size nine-panel TPS array. This array was subjected to simulated shuttle missions of both thermal and acoustic loading. Results are presented which illustrate the structural and thermal adequacy under uniform heating and manufacturability of a full-size coated columbium-alloy TPS which is lightweight, reliable, and reusable.

Rummler, D. R.↗
NASA NTRS2002

Preliminary Thermal-Mechanical Sizing of Metallic TPS: Process Development and Sensitivity Studies

The purpose of this research was to perform sensitivity studies and develop a process to perform thermal and structural analysis and sizing of the latest Metallic Thermal Protection System (TPS) developed at NASA LaRC (Langley Research Center). Metallic TPS is a key technology for reducing the cost of reusable launch vehicles (RLV), offering the combination of increased durability and competitive weights when compared to other systems. Accurate sizing of metallic TPS requires combined thermal and structural analysis. Initial sensitivity studies were conducted using transient one-dimensional finite element thermal analysis to determine the influence of various TPS and analysis parameters on TPS weight. The thermal analysis model was then used in combination with static deflection and failure mode analysis of the sandwich panel outer surface of the TPS to obtain minimum weight TPS configurations at three vehicle stations on the windward centerline of a representative RLV. The coupled nature of the analysis requires an iterative analysis process, which will be described herein. Findings from the sensitivity analysis are reported, along with TPS designs at the three RLV vehicle stations considered.

Poteet, Carl C.↗
NASA NTRS1974

Data correlation and analysis of arc tunnel and wind tunnel tests of RSI joints and gaps. Volume 2: Data base

Wind tunnel tests were conducted to determine the aerodynamic heating created by gaps in the reusable surface insulation (RSI) thermal protection system (TPS) for the space shuttle. The effects of various parameters of the RSI on convective heating characteristics are described. The wind tunnel tests provided a data base for accurate assessment of gap heating. Analysis and correlation of the data provide methods for predicting heating in the RSI gaps on the space shuttle.

Christensen, H. E.↗
NASA NTRS1975

Data correlation and analysis of arc tunnel and wind tunnel tests of RSI joints and gaps, phase 2. Volume 1: Technical report

Heat transfer data measured in gaps representative of those being employed for joints in the space shuttle reusable surface insulation (RSI) thermal protection systems (TPS) were assimilated, analyzed, and correlated. Several types of gap were investigated with emphasis on simple butt joints. Gap widths ranged from 0.0 to 0.76 cm and depths ranged from 1 to 6 cm. Laminar, transitional, and turbulent boundary layer flows over the gap opening were investigated. The angle between gap axis and external flow was varied between 0 and pi/2 radians. The contoured cross section gap performed significantly better than all other wide gaps and slightly better than all other narrow gap geometries. Three dimensional heating variations were observed within gaps in the absence of external flow pressure gradients. Interactions between heating within gaps and heating of adjacent top tile surfaces were observed. Gaps aligned with the flow were observed to promote boundary layer transition. Heat transfer correlation equations were obtained for many of the tests. The TPS thickness requirements with and without gaps were computed for a current shuttle entry trajectory. Experimental data employed in the study are summarized. A description of each test facility, run schedule and test conditions, model descriptive information, and heat flux data are included.

Cristensen, H. E.↗
NASA NTRS1980

An assessment of the readiness of ablative materials for preflight application to the shuttle orbiter

The shuttle orbiter relies primarily on a reusable surface insulation (RSI) thermal protection system (TPS). The RSI is very efficient in its thermal performance; however, the RSI tile system has shown poor mechanical integrity. The state-of-the-art of the ablative TPS is reviewed, and an assessment made of the ablator's readiness for use on the shuttle orbiter. Unresolved technical issues with regard to the ablative TPS are identified. Short time, highly focused analytical and experimental programs were initiated to: (1) identify candidate ablation materials; (2) assess the data base for these materials; (3) evaluate the need and kind of waterproof coating; (4) calculate thermal and other stresses in an ablator tile; (5) identify an acceptable ablator/RSI tile joint filler; and (6) assess the sensitivity of the ablator to sequential heat pulses. Results from some of these programs are discussed.

Tompkins, S. S.↗
NASA NTRS1983

Space shuttle orbiter reusable surface insulation flight results

The first five flights of the orbiter Columbia provided the initial data required to certify the operational performance of the reusable surface insulation (RSI) thermal protection system (TPS). The flight performance characteristics of the RIS TPS are discussed. The discussion is based primarily on postflight inspections and postflight interpretation of the flight instrumentation. TPS modifications of the future orbiters (OV-099, 103, and subs) are also discussed.

Dotts, R. L.↗
NASA NTRS1986

Ceramic-ceramic shell tile thermal protection system and method thereof

A ceramic reusable, externally applied composite thermal protection system (TPS) is proposed. The system functions by utilizing a ceramic/ceramic upper shell structure which effectively separates its primary functions as a thermal insulator and as a load carrier to transmit loads to the cold structure. The composite tile system also prevents impact damage to the atmospheric entry vehicle thermal protection system. The composite tile comprises a structurally strong upper ceramic/ceramic shell manufactured from ceramic fibers and ceramic matrix meeting the thermal and structural requirements of a tile used on a re-entry aerospace vehicle. In addition, a lightweight high temperature ceramic lower temperature base tile is used. The upper shell and lower tile are attached by means effective to withstand the extreme temperatures (3000 to 3200F) and stress conditions. The composite tile may include one or more layers of variable density rigid or flexible thermal insulation. The assembly of the overall tile is facilitated by two or more locking mechanisms on opposing sides of the overall tile assembly. The assembly may occur subsequent to the installation of the lower shell tile on the spacecraft structural skin.

Riccitiello, Salvatore R.↗
NASA NTRS1999

Aerothermal Test of Thermal Protection Systems for X-33 Reusable Launch Vehicle

An array of metallic Thermal Protection System (TPS) panels developed for the windward surface of the X-33 vehicle was tested in the 8-Foot High Temperature Tunnel at the NASA Langley Research Center. These tests were the first aerothermal tests of an X-33 TPS array and the test results will be used to validate the TPS for the X-33 flight program. Specifically, the tests evaluated the structural and thermal performance of the TPS, the effectiveness of the high temperature seals between adjacent panels and the durability of the TPS under realistic aerothermal flight conditions. The effect of varying panel-to-panel step heights, intentional damage to the seals between adjacent panels, and the use of secondary seals were also investigated during the test program. The metallic TPS developed for the windward surface of the X-33, the blanket TPS developed to protect the leeward surfaces of the X-33, and the test program in the 8-Foot High Temperature Tunnel are presented and discussed.

Sawyer, James Wayne↗
NASA NTRS1975

Performance of full size metallic and RSI thermal protection systems in a Mach 7 environment

The integrity and reusability of three flight-weight metallic and RSI thermal protection systems, designed for the Shuttle entry environment, have been demonstrated. Each model successfully survived over 23 entry thermal cycles without serious degradation. The metallic systems were more tolerant of the hostile environment and provided a higher degree of reusability than did the RSI. Thermal expansion slip joints of the metallic TPS successfully prevented hot gas ingress to the substructure. The RSI demonstrated high damage tolerance and field repairs increased its reusability. Heat-transfer tests to further assess RSI gap heating indicate that stacked tile orientations may impose a penalty on tile thickness. Parameters influencing RSI impingement heating were determined, and the heating data were correlated.

Bohon, H. L.↗
NASA NTRS1998

Measuring Thermal Conductivity and Moisture Absorption of Cryo-Insulation Materials

NASA is seeking to develop thermal insulation material systems suitable for withstanding both extremely high temperatures encountered during atmospheric re-entry heating and aero- braking maneuvers, as well as extremely low temperatures existing in liquid fuel storage tanks. Currently, materials used for the high temperature insulation or Thermal Protection System (TPS) are different from the low temperature, or cryogenic insulation. Dual purpose materials are necessary to the development of reusable launch vehicles (RLV). The present Space Shuttle (or Space Transportation System, STS) employs TPS materials on the orbiter and cryo-insulation materials on the large fuel tank slung under the orbiter. The expensive fuel tank is jettisoned just before orbit is achieved and it burns up while re-entering over the Indian Ocean. A truly completely reusable launch vehicle must store aR cryogenic fuel internally. The fuel tanks will be located close to the outer surface. In fact the outer skin of the craft will probably also serve as the fuel tank enclosure, as in jet airliners. During a normal launch the combined TPS/cryo-insulation system will serve only as a low temperature insulator, since aerodynamic heating is relatively minimal during ascent to orbit. During re-entry, the combined TPS/cryo-insulation system will serve only as a high temperature insulator, since all the cryogenic fuel will have been expended in orbit. However, in the event of an.aborted launch or a forced/emergency early re-entry, the tanks will still contain fuel, and the TPS/cryo-insulation will have to serve as both low and high temperature insulation. Also, on long duration missions, such as to Mars, very effective cryo-insulation materials are needed to reduce bod off of liquid propellants, thereby reducing necessary tankage volume, weight, and cost. The conventional approach to obtaining both low and high temperature insulation, such as is employed for the X-33 and X-34 spacecraft, is to use separate TPS and cryo-insulation materials, which are connected by means of adhesives or stand-offs (spacers). Three concepts are being considered: (1) the TPS is bonded directly to the cryo-insulation which, in turn, is bonded to the exterior of the tank, (2) stand-offs are used to make a gap between the TPS and the cryo-insulation, which is bonded externally to the tank, (3) TPS is applied directly or with stand-offs to the exterior so the tank, and cryo-insulation is applied directly to the interior of the tank. Many potential problems are inherent in these approaches. For example, mismatch between coefficients of thermal expansion of the TPS and cryo-insulation, as well as aerodynamic loads, could lead to failure of the bond. Internal cryo-insulation must be prevent from entering the sump of the fuel turbo-pump. The mechanical integrity of the stand-off structure (if used) must withstand multiple missions. During ground hold (i.e., prior to launch) moisture condensation must be minimized in the gap between the cryo-insulation and the TPS. The longer term solution requires the development of a single material to act as cryo- insulation during ground hold and as TPS during re-entry. Such a material minimizes complexity and weight while improving reliability and reducing cost.

Lambert, Michael A.↗
NASA NTRS1995

Reusable LH2 tank technology demonstration through ground test

The paper presents the project plan to demonstrate, by March 1997, the reusability of an integrated composite LH2 tank structure, cryogenic insulation, and thermal protection system (TPS). The plan includes establishment of design requirements and a comprehensive trade study to select the most suitable Reusable Hydrogen Composite Tank system (RHCTS) within the most suitable of 4 candidate structural configurations. The 4 vehicles are winged body with the capability to deliver 25,000 lbs of payload to a circular 220 nm, 51.6 degree inclined orbit (also 40,000 lbs to a 28.5 inclined 150 nm orbit). A prototype design of the selected RHCTS is established to identify the construction, fabrication, and stress simulation and test requirements necessary in an 8 foot diameter tank structure/insulation/TPS test article. A comprehensive development test program supports the 8 foot test article development and involves the composite tank itself, cryogenic insulation, and integrated tank/insulation/TPS designs. The 8 foot diameter tank will contain the integrated cryogenic insulation and TPS designs resulting from this development and that of the concurrent lightweight durable TPS program. Tank ground testing will include 330 cycles of LH2 filling, pressurization, body loading, depressurization, draining, and entry heating.

Bianca, C.↗