Results for “Thermal Protection System (TPS)” — Page 4

NASA NTRS2026

PROTECT: Production and Reuse of Thermally Efficient Ceramic Thermal Protection Systems

PROTECT (Production and Reuse Of Thermally Efficient Ceramic TPS) is a NASA Early Career Initiative focused on developing the next generation of reusable ceramic thermal protection systems (TPS). This project addresses key challenges in TPS design, including temperature capability, thermal stability, and refurbishment time, by integrating novel material development with predictive modeling. Leveraging enhanced capabilities in NASA’s Porous Microstructure Analysis (PuMA) software, PROTECT introduces new modeling tools to predict the thermal and mechanical behavior of fibrous ceramic materials. These tools enable accurate prediction of performance metrics such as thermal conductivity and structural integrity, reducing reliance on costly physical testing. Preliminary advances in these areas will be presented. To support model validation, PROTECT is building a comprehensive database of raw material properties using advanced characterization techniques, including micro computed tomography (CT) scanning in collaboration with the University of Illinois Urbana-Champaign (UIUC). The presentation will detail the sampling workflows and analysis methods used to generate this detailed microstructural data and how it is used to develop improved models in PuMA. This multi-center collaboration, spanning NASA (JSC, ARC, KSC, GRC), Oak Ridge National Laboratory, UIUC, and SpaceX, is developing tailored TPS solutions for LEO, lunar, and Martian missions. By bridging heritage systems with the demands of modern spaceflight, PROTECT contributes to the advancement of reusable TPS technologies for future exploration missions.

Propulsion, Refractory, and Coating Materials↗

NASA NTRS2026

PROTECT: Production and Reuse of Thermally Efficient Ceramic Thermal Protection Systems

PROTECT (Production and Reuse Of Thermally Efficient Ceramic TPS) is a NASA Early Career Initiative focused on developing the next generation of reusable ceramic thermal protection systems (TPS). This project addresses key challenges in TPS design, including temperature capability, thermal stability, and refurbishment time, by integrating novel material development with predictive modeling. Leveraging enhanced capabilities in NASA’s Porous Microstructure Analysis (PuMA) software, PROTECT introduces new modeling tools to predict the thermal and mechanical behavior of fibrous ceramic materials. These tools enable accurate prediction of performance metrics such as thermal conductivity and structural integrity, reducing reliance on costly physical testing. Preliminary advances in these areas will be presented. To support model validation, PROTECT is building a comprehensive database of raw material properties using advanced characterization techniques, including micro computed tomography (CT) scanning in collaboration with the University of Illinois Urbana-Champaign (UIUC). The presentation will detail the sampling workflows and analysis methods used to generate this detailed microstructural data and how it is used to develop improved models in PuMA. This multi-center collaboration, spanning NASA (JSC, ARC, KSC, GRC), Oak Ridge National Laboratory, UIUC, and SpaceX, is developing tailored TPS solutions for LEO, lunar, and Martian missions. By bridging heritage systems with the demands of modern spaceflight, PROTECT contributes to the advancement of reusable TPS technologies for future exploration missions.

Propulsion, Refractory, and Coating Materials↗

NASA NTRS1992

Predicted and tested performance of durable TPS

The development of thermal protection systems (TPS) for aerospace vehicles involves combining material selection, concept design, and verification tests to evaluate the effectiveness of the system. The present paper reviews verification tests of two metallic and one carbon-carbon thermal protection system. The test conditions are, in general, representative of Space Shuttle design flight conditions which may be more or less severe than conditions required for future space transportation systems. The results of this study are intended to help establish a preliminary data base from which the designers of future entry vehicles can evaluate the applicability of future concepts to their vehicles.

Shideler, John L.↗

NASA NTRS2020

InSight Aerothermal Environment Assessment

The Mars Interior Exploration using Seismic Investigations, Geodesy and Heat Transport (InSight) spacecraft, which successfully touched down on the planet surface on November 26, 2018, was proposed as a near build-to-print copy of the Mars Phoenix vehicle to reduce the overall cost and risk of the mission. Since the lander payload and the atmospheric entry trajectory were similar enough to those of the Phoenix mission, it was expected that the Phoenix thermal protection material thickness would be sufficient to withstand the entry heat load. However, allowances were made for increasing the heatshield thickness because the planned spacecraft arrival date coincided with the Mars dust storm season. The aftbody Thermal Protection System (TPS) components were not expected to change. In a first for a US Mars mission, the aerothermal environments for InSight included estimates of radiative heat flux to the aftbody from the wake. The combined convective and radiative heat fluxes were used to determine if the as-flown Phoenix thermal protection system (TPS) design would be sufficient for InSight. Although the radiative heat fluxes on the aftbody were predicted to be comparable to, or even higher than the local convective heat fluxes, all analyses of the aftbody TPS showed that the design would still be adequate. Aerothermal environments were computed for the vehicle from post-flight reconstruction of the atmosphere and trajectory and compared.

Beck, Robin↗

NASA NTRS2020

InSight Aerothermal Environment Assessment

The Mars Interior Exploration using Seismic Investigations, Geodesy and Heat Transport (InSight) spacecraft, which successfully touched down on the planet surface on November 26, 2018, was proposed as a near build-to-print copy of the Mars Phoenix vehicle to reduce the overall cost and risk of the mission. Since the lander payload and the atmospheric entry trajectory were similar enough to those of the Phoenix mission, it was expected that the Phoenix thermal protection material thickness would be sufficient to withstand the entry heat load. However, allowances were made for increasing the heatshield thickness because the planned spacecraft arrival date coincided with the Mars dust storm season. The aftbody Thermal Protection System (TPS) components were not expected to change. In a first for a US Mars mission, the aerothermal environments for InSight included estimates of radiative heat flux to the aftbody from the wake. The combined convective and radiative heat fluxes were used to determine if the as-flown Phoenix thermal protection system (TPS) design would be sufficient for InSight. Although the radiative heat fluxes on the aftbody were predicted to be comparable to, or even higher than the local convective heat fluxes, all analyses of the aftbody TPS showed that the design would still be adequate. Aerothermal environments were computed for the vehicle from post-flight reconstruction of the atmosphere and trajectory and compared with the design environments. These comparisons showed that the predicted as-flown conditions were less severe than the design conditions.

Beck, Robin A. S.↗

NASA NTRS2006

Space Shuttle Thermal Protection System Repair Flight Experiment Induced Contamination Impacts

NASA s activities to prepare for Flight LF1 (STS-114) included development of a method to repair the Thermal Protection System (TPS) of the Orbiter s leading edge should it be damaged during ascent by impacts from foam, ice, etc . Reinforced Carbon-Carbon (RCC) is used for the leading edge TPS. The repair material that was developed is named Non- Oxide Adhesive eXperimental (NOAX). NOAX is an uncured adhesive material that acts as an ablative repair material. NOAX completes curing during the Orbiter s descent. The Thermal Protection System (TPS) Detailed Test Objective 848 (DTO 848) performed on Flight LF1 (STS-114) characterized the working life, porosity void size in a micro-gravity environment, and the on-orbit performance of the repairs to pre-damaged samples. DTO 848 is also scheduled for Flight ULF1.1 (STS-121) for further characterization of NOAX on-orbit performance. Due to the high material outgassing rates of the NOAX material and concerns with contamination impacts to optically sensitive surfaces, ASTM E 1559 outgassing tests were performed to determine NOAX condensable outgassing rates as a function of time and temperature. Sensitive surfaces of concern include the Extravehicular Mobility Unit (EMU) visor, cameras, and other sensors in proximity to the experiment during the initial time after application. This paper discusses NOAX outgassing characteristics, how the amount of deposition on optically sensitive surfaces while the NOAX is being manipulated on the pre-damaged RCC samples was determined by analysis, and how flight rules were developed to protect those optically sensitive surfaces from excessive contamination where necessary.

Smith, Kendall A.↗

NASA NTRS2003

Current Developments in Future Planetary Probe Sensors for TPS

In-situ Thermal Protection System (TPS) sensors are required to provide traceability of TPS performance and sizing tools. Traceability will lead to higher fidelity design tools, which in turn will lead to lower design safety margins, and decreased heatshield mass. Decreasing TPS mass will enable certain missions that are not otherwise feasible, and directly increase science payload. NASA Ames is currently developing two flight measurements as essential to advancing the state of TPS traceability for material modeling and aerothermal simulation: heat flux and surface recession (for ablators). The heat flux gage is applicable to both ablators and non-ablators and is therefore the more generalized sensor concept of the two with wider applicability to mission scenarios. This paper describes the development of a microsensor capable of surface and in-depth temperature and heat flux measurements for TPS materials appropriate to Titan, Neptune, and Mars aerocapture, and direct entry. The thermal sensor will be monolithic solid state devices composed of thick film platinum RTD on an alumina substrate. Choice of materials and critical dimensions are used to tailor gage response, determined during calibration activities, to specific (forebody vs. aftbody) heating environments. Current design has maximum operating temperature of 1500 K, and allowable constant heat flux of q=28.7 watts per square centimeter, and time constants between 0.05 and 0.2 seconds. The catalytic and radiative response of these heat flux gages can also be changed through the use of appropriate coatings. By using several co-located gages with various surface coatings, data can be obtained to isolate surface heat flux components due to radiation, catalycity and convection. Selectivity to radiative heat flux is a useful feature even for an in-depth gage, as radiative transport may be a significant heat transport mechanism for porous TPS materials in Titan aerocapture. This paper also reports on progress to adapt a previously flown surface recession sensor, based on the Jupiter probe Galileo Analog Resistance Ablation Detector (ARAD), to appropriate aerocapture conditions.

Martinez, Ed↗

NASA NTRS2001

A Method of Integrating Aeroheating into Conceptual Reusable Launch Vehicle Design: Evaluation of Advanced Thermal Protection Techniques for Future Reusable Launch Vehicles

A method for integrating Aeroheating analysis into conceptual reusable launch vehicle (RLV) design is presented in this thesis. This process allows for faster turn-around time to converge a RLV design through the advent of designing an optimized thermal protection system (TPS). It consists of the coupling and automation of four computer software packages: MINIVER, TPSX, TCAT, and ADS. MINIVER is an Aeroheating code that produces centerline radiation equilibrium temperatures, convective heating rates, and heat loads over simplified vehicle geometries. These include flat plates and swept cylinders that model wings and leading edges, respectively. TPSX is a NASA Ames material properties database that is available on the World Wide Web. The newly developed Thermal Calculation Analysis Tool (TCAT) uses finite difference methods to carry out a transient in-depth 1-D conduction analysis over the center mold line of the vehicle. This is used along with the Automated Design Synthesis (ADS) code to correctly size the vehicle's thermal protection system (TPS). The numerical optimizer ADS uses algorithms that solve constrained and unconstrained design problems. The resulting outputs for this process are TPS material types, unit thicknesses, and acreage percentages. TCAT was developed for several purposes. First, it provides a means to calculate the transient in-depth conduction seen by the surface of the TPS material that protects a vehicle during ascent and reentry. Along with the in-depth conduction, radiation from the surface of the material is calculated along with the temperatures at the backface and interior parts of the TPS material. Secondly, TCAT contributes added speed and automation to the overall design process. Another motivation in the development of TCAT is optimization. In some vehicles, the TPS accounts for a high percentage of the overall vehicle dry weight. Optimizing the weight of the TPS will thereby lower the percentage of the dry weight accounted for by the TPS. Also, this will lower the cost of the TPS and the overall cost of the vehicle.

Olds, John R.↗

DOE OSTI2022

DESIGN AND TESTING OF DIMES CARBON ABLATION RODS IN THE DIII-D TOKAMAK

We present the design of ATJ graphite rods developed for ablation experiments under high heat flux (up to 50 MW/m2) in the lower divertor of the DIII-D tokamak, a magnetic plasma confinement device. This work is motivated by the need to test ablation models relevant to carbon-based thermal shields used in high-speed spacecraft atmospheric entries, where the heat fluxes encountered can be comparable to those achieved in the DIII-D divertor plasma. Several different designs for the flowfacing side of the rod are analyzed, including "sharp nose," "blunt," and "concave". The last shape is studied for its potential to lower heat fluxes at the rod surface by increased radiation from trapped neutrals and reduced parallel plasma pressure. We also analyze the possibility of applying a thin (approximately 30 microns) layer of silicon carbide (SiC) to the exposed part of several carbon ablation rods to benchmark its erosion calculations and lifetime predictions. Such calculations are of interest as SiC represents a promising material for both thermal protection systems (TPS) and a fusion plasma-facing material (PFM). Preliminary results from the DIII-D rod ablation experiments are also discussed.

Orlov, Dmitri M.↗

NASA NTRS1982

Structural characteristics of the shuttle orbiter ceramic thermal protection system

The thermal protection system (TPS) of the Space Shuttle Orbiter is described as well as the results of dynamic reponse studies conducted in support of the efforts to certify the TPS for flight. The ceramic Thermal Protection System consists of ceramic tiles bonded to felt pads which are in turn bonded to the Orbiter substructure to protect the aluminum substructure from the heat of reentry.

Cooper, P. A.↗

NASA NTRS2015

Thermal Testing of the Heatshield for Extreme Entry Environment Technology (HEEET) TPS

The testing of a thermal protection system (TPS) in multiple arc jets and laser facilities is critical not only to determine the ability of a material to withstand the harsh aerothermal environments but is also required to collect relevant data that allows construction of a thermal response model of the TPS for flight design. The present talk provides an overview of recent arcjet testing of the HEEET material, one of the families of materials from the 3D Woven TPS program, being developed under NASAs Heatshield for Extreme Entry Environment Technology (HEEET) project.

Gasch, M,↗

NASA NTRSDate not supplied

Advances in Design Capabilities for Planetary Missions from the NASA Entry Systems Modeling and Instrumentation Portfolio

The Entry Systems Modeling project (ESM) is supported by both the NASA Space Technology and the Science Mission Directorates and focuses on developing simulation tools and validated models for characterizing the performance of entry systems tailored to planetary destinations across the Solar System. ESM is organized into six technical capability areas that together address all relevant factors related to spacecraft entry, as well as some aspects of descent: Thermal Protection System (TPS) Materials; Aerothermodynamics; Entry & Descent Vehicle Dynamics; Guidance, Navigation, and Control; Vehicle Systems Analysis; and Advanced Tools and Numerical Methods. Development within the capability areas is undertaken explicitly with a focus on transition and infusion to science missions, human exploration missions, and commercial space activities. The present talk details developments that specifically impact science missions, including simulation tool capabilities that aid in mission design and model development to understand entry system performance at a given destination. Examples of the successful infusion and transition of such project outcomes to science missions also are provided. Several simulation tool development efforts within ESM have resulted in new design capabilities for missions. One such outcome is improved toolsets for mission trajectory and concept of operations design. Specifically, an initiative to couple a leading tool for entry, ascent/descent, and orbital trajectory optimization (Program to Optimize Simulated Trajectories II or POST2) to those used within the Agency for interplanetary trajectory optimization (Copernicus and Monte) has made substantial progress, with the outcomes to date promising to allow efficient trajectory optimization across mission phases. Additionally, toolchains for the evaluation of vehicle performance during entry and descent have been developed that allow assessment of multi-dimensional aeroheating on detailed vehicle geometries, characterization of deployment and inflation of parachutes, and assessment of vehicle dynamic stability during descent. These capabilities are achieved by coupling diverse sets of physics together – material response, computational fluid dynamics, radiation, and vehicle dynamics – to suitably describe complex entry and descent phenomena. Several model development and validation efforts for specific destinations and entry regimes also are underway within the ESM project. For instance, new experimental capabilities to validate radiation models at low densities/high altitudes recently have been established with project support, specifically the Low-Density Shock Tube (LDST) at the NASA Ames Research Center Electric Arc Shock Tube (EAST) facility. The LDST is being leveraged to develop improved models of shock layer kinetics and radiation in Titan atmospheres, while future studies will be conducted in the LDST and the existing high velocity shock tube to provide validation data for radiation models of Venus, Ice Giants, and Mars atmospheres. Models describing the aerothermal and thermo-structural performance of Thermal Protection System (TPS) materials has been another focus, with multiscale modeling activities on-going for the two leading TPS materials applicable to a range of entry conditions and science missions: the Phenolic-Impregnated Carbon Ablator (PICA) and woven materials like 3D Mid-Density Carbon Phenolic (3MDCP). A continual effort is made to infuse and transition outcomes from ESM simulation tool and model development activities into relevant science missions. Significant progress has been made on this front, with missions such as Dragonfly, DAVINCI, and Mars Missions benefitting from project outcomes. The groundwork also is being laid to provide insights into forward looking missions to Gas/Ice Giants as well as for potential sample returns.

Justin Haskins↗

NASA NTRSDate not supplied

NASA Efforts to Explore Additively Manufactured Thermal Protection Systems (AM TPS)

Explore the source record for details and available documents.

Adam T. Sidor↗

NASA NTRS2003

Aerogel Composites for Aerospace Thermal Protection

Aerogel composites formed by infiltrating organic and/or inorganic aerogels into fiber matrix materials enable us to exploit the low thermal conductivity and low density of aerogels while maintaining the strength, structure and other useful properties of a porous fiber matrix. New materials for extreme heating ranges are needed to insulate future spacecraft against the extreme heat of planetary atmospheric entry, but the insulation mass must be minimized in order to maximize the payload. A reusable system passively insulates to survive heating unchanged for relatively low heating. Ablators, which sacrifice mass to control heating, are used to protect vehicles against more extreme heating for a single use thermal protection system (TPS). Aerogel composites were fabricated and tested for spacecraft thermal protection. The high-temperaturey high heat flux tests described in this paper were performed in NASA Ames arc-jet facilities to simulate spacecraft atmospheric entry, and include heating conditions predicted for the forebody and backshell of the Mars Science Lander (MSL) entry probe. The aerogel composites tested showed excellent thermal performance in the arc-jet tests, functioning both as reusuable insulation under lower heat fluxes, and as ablative aerogels under the extreme heating predicted for the MSL forebody.

White, Susan↗

NASA NTRS2005

Development of Solid State Thermal Sensors for Aeroshell TPS Flight Applications

In-situ Thermal Protection System (TPS) sensors are required to provide verification by traceability of TPS performance and sizing tools. Traceability will lead to higher fidelity design tools, which in turn will lead to lower design safety margins, and decreased heatshield mass. Decreasing TPS mass will enable certain missions that are not otherwise feasible, and directly increase science payload. NASA Ames is currently developing two flight measurements as essential to advancing the state of TPS traceability for material modeling and aerothermal simulation: heat flux and surface recession (for ablators). The heat flux gage is applicable to both ablators and non-ablators and is therefore the more generalized sensor concept of the two with wider applicability to mission scenarios. This paper describes the continuing development of a thermal microsensor capable of surface and in-depth temperature and heat flux measurements for TPS materials appropriate to Titan, Neptune, and Mars aerocapture, and direct entry. The thermal sensor is a monolithic solid state device composed of thick film platinum RTD on an alumina substrate. Choice of materials and critical dimensions are used to tailor gage response, determined during calibration activities, to specific (forebody vs. aftbody) heating environments. Current design has maximum operating temperature of 1500K, and allowable constant heat flux of q=28.7 W/cm(sup 2), and time constants between 0.05 and 0.2 seconds. The catalytic and radiative response of these heat flux gages can also be changed through the use of appropriate coatings. By using several co-located gages with various surface coatings, data can be obtained to isolate surface heat flux components due to radiation, catalycity and convection. Selectivity to radiative heat flux is a useful feature even for an in-depth gage, as radiative transport may be a significant heat transport mechanism for porous TPS materials in Titan aerocapture.

Martinez, Ed↗

NASA NTRS2014

Woven Thermal Protection System (WTPS) a Novel Approach to Meet NASA's Most Demanding Reentry Missions

NASA's future robotic missions to Venus and outer planets, namely, Saturn, Uranus, Neptune, result in extremely high entry conditions that exceed the capabilities of current mid-density ablators (PICA or Avcoat). Therefore mission planners assume the use of a fully dense carbon phenolic heat shield similar to what was flown on Pioneer Venus and Galileo. Carbon phenolic (CP) is a robust Thermal Protection System (TPS) however its high density and thermal conductivity constrain mission planners to steep entries, high heat fluxes, pressures and short entry durations, in order for CP to be feasible from a mass perspective. The high entry conditions pose certification challenges in existing ground based test facilities. In 2012 the Game Changing Development Program in NASA's Space Technology Mission Directorate funded NASA ARC to investigate the feasibility of a Woven Thermal Protection System (WTPS) to meet the needs of NASA's most challenging entry missions. This presentation will summarize maturation of the WTPS project.

carbon phenolic↗

NASA NTRS1987

Development and test of the Shuttle/Centaur cryogenic tankage thermal protection system

The Thermal Protection System (TPS) for the Shuttle/Centaur had to provide fail-safe thermal protection during prelaunch, launch ascent, and on-orbit operations as well as during potential abort where the Shuttle and Centaur would return to earth. The TPS selected used a helium-purged polyimide foam beneath three radiation shields for the liquid hydrogen (LH2) tank and radiation shields only for the liquid oxygen (LO2) tank (three shields on the tank sidewall and four on the aft bulkhead). An evacuated common intermediate bulkhead separated the two tanks. The LH2 tank had one 1.9-cm thick layer of foam on the forward bulkhead and two layers on the larger area side-wall. Full scale tests of the flight vehicle in a simulated Shuttle cargo bay, that was purged with gaseous nitrogen, gave total prelaunch heating rates of 25.9 kW and 12.9 kW for LH2 and LO2 tanks, respectively. Calorimeter tests on a representative LH2 tank sidewall TPS sample indicated that the measured unit heating rate would rapidly decrease from the prelaunch rate of 300 W/sq m to a desired rate of less than 4 W/sq m once on-orbit.

Knoll, R. H.↗

NASA NTRS1990

NDE of thermal protection system for space shuttle solid rocket booster

Potential nondestructive test (NDE) methods were evaluated for detecting debonds and weak bonds in the thermal protection system (TPS) for the space shuttle solid rocket boosters. The primary thermal protection material is a sprayable, thick epoxy coating that is filled with lightweight and thermal insulating materials. Test panels were fabricated with a wide variety of hidden realistic defects, including contact debonds and weak bonds. Nondestructive test results were obtained. Candidate NDE methods evaluated for booster production applications include laser interferometry (e.g., electronic shearography), infrared thermography, radiography (e.g., computed tomography), acousto-ultrasonics, mechanical/acoustic impedance, ultrasonics, acoustic emission, and the tap test. Capabilities, advantages, disadvantages, and relative performances in defect detection of each test method for TPS bonding applications are reported. Electronic shearography NDE was technically the superior method for detecting debonds.

Myers, R. S.↗