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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 NTRS2004

A Coating That Cools and Cuts Costs

To enable low-cost space access for advanced exploration vehicles, researchers from NASA's Ames Research Center invented and patented a protective coating for ceramic materials (PCCM) in 1994. The technology, originally intended to coat the heat shields of the X-33 and X-34 next-generation vehicles for optimum protection during atmospheric reentry, greatly reduces surface temperature of a thermal control structure while it reradiates absorbed energy to a cooler surface or body, thus preventing degradation of the underlying ceramic material.

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NASA NTRS2005

Genesis: Removing Contamination from Sample Collectors

The Genesis mission returned to Earth on September 8, 2004, experiencing a non-nominal reentry. The parachutes which were supposed to slow and stabilize the capsule throughout the return failed to deploy, causing the capsule to impact the desert floor at a speed of nearly 200 MPH. Both the science canister and the major components of the SRC were returned before nightfall on September 8 to the prestaged cleanroom at UTTR , avoiding prolonged exposure or pending weather changes which might further contaminate the samples. The majority of the contaminants introduced as a result of the anomalous landing were in the form of particulates, including UTTR dust and soil, carbon-carbon heat shield material, and shattered collector dust (primarily silicon and germanium). Additional information is included in the original extended abstract.

Lauer, H. V.↗
NASA NTRS2005

Genesis Preliminary Examination: Ellipsometry Overview

The Genesis spacecraft returned to Earth on September 8, 2004, experiencing a non-nominal reentry in which both the drogue and main parachutes failed to deploy causing the capsule to impact the surface of the UTTR desert at a speed of approximately 310 kph (193 mph). The impact caused severe damage to the capsule and a breach of the science canister in the field. The science canister was recovered and transported to the cleanroom at UTTR within approximately 8 hours of reentry. Although the ground water table did not rise to canister level before removal, damp soil and debris from the heat shield and other spacecraft components did enter the canister and contaminate some collector surfaces. The objective of preliminary examination of the Genesis collectors is to provide the science community with the information necessary to request the most useful samples for their analysis.

Stansbery, E. K.↗
NASA NTRS2005

Prediction of the Aerothermodynamic Environment of the Huygens Probe

An investigation of the aerothermodynamic environment of the Huygens entry probe has been conducted. A Monte Carlo simulation of the trajectory of the probe during entry into Titan's atmosphere was performed to identify a worst-case heating rate trajectory. Flowfield and radiation transport computations were performed at points along this trajectory to obtain convective and radiative heat-transfer distributions on the probe's heat shield. This investigation identified important physical and numerical factors, including atmospheric CH4 concentration, transition to turbulence, numerical diffusion modeling, and radiation modeling, which strongly influenced the aerothermodynamic environment.

Hollis, Brian R.↗
NASA NTRS2005

Space Shuttle Main Engine Debris Testing Methodology and Impact Tolerances

In the wake of the Space Shuttle Columbia disaster every effort is being made to determine the susceptibility of Space Shuttle elements to debris impacts. Ice and frost debris is formed around the aft heat shield closure of the orbiter and liquid hydrogen feedlines. This debris has been observed to liberate upon lift-off of the shuttle and presents potentially dangerous conditions to the Space Shuttle Main Engine. This paper describes the testing done to determine the impact tolerance of the Space Shuttle Main Engine nozzle coolant tubes to ice strikes originating from the launch pad or other parts of the shuttle.

Gradl, Paul R.↗
NASA NTRS2005

Atmospheric Models for Mars Aerocapture

level Mars atmospheric model. Applications include systems design, performance analysis, and operations planning for aerobraking, entry descent and landing, and aerocapture. Typical Mars aerocapture periapsis altitudes (for systems with rigid- aeroshell heat shields) are about 50 km. This altitude is above the 0-40 km height range covered by Mars Global Surveyor Thermal Emission Spectrometer (TES) nadir observations. Recently, TES limb sounding data have been made available, spanning more than two Mars years (more than 200,000 data profiles) with altitude coverage up to about 60 km, well within the height range of interest for aerocapture. Results are presented comparing Mars-GRAM atmospheric density with densities from TES nadir and limb sounding observations. A new Mars-GRAM feature is described which allows individual TES nadir or limb profiles to be extracted from the large TES databases, and to be used as an optional replacement for standard Mars-GRAM background (climatology) conditions. For Monte-Carlo applications such as aerocapture guidance and control studies, Mars-GRAM perturbations are available using these TES profile background conditions.

Justus, C. G.↗
NASA NTRS2005

Genesis Noble Gas Measurements

The original thrust of our Genesis funding was to extend and refine the noble gas analytical capabilities of this laboratory to improve the precision and accuracy of noble gas measurements in order to optimize the scientific return from the Genesis Mission. This process involved both instrumental improvement (supplemented by a SRLIDAP instrument grant) and refinement of technique. The Genesis landing mishap shifted our emphasis to the irregular aluminum heat shield material from the flat collector wafers. This has required redesign of our laser extraction cells to accommodate the longer focal lengths required for laser extraction from non-flat surfaces. Extraction of noble gases from solid aluminum surfaces, rather than thin coatings on transparent substrates has required refinement of controlled-depth laser ablation techniques. Both of these bring new problems, both with potentially higher blanks form larger laser cells and the larger quantities of evaporated aluminum which can coat the sapphire entrance ports. This is mainly a problem for the heavy noble gases where larger extraction areas are required, necessitating the new aluminum vapor containment techniques described below. With the Genesis Mission came three new multiple multiplier noble gas mass spectrometers to this laboratory, one built solely by us (Supergnome-M), one built in collaboration with Nu-Instruments (Noblesse), and one built in collaboration with GVI (Helix). All of these have multiple multiplier detection sections with the Nu-Instruments using a pair of electrostatic quad lenses for isotope spacing and the other two using mechanically adjustable positions for the electron multipliers. The Supergnome-M and Noblesse are installed and running. The GVI instrument was delivered a year late (in March 2005) and is yet to be installed by GVI. As with all new instruments there were some initial development issues, some of which are still outstanding. The most serious of these are performance issues with the miniature channel electron multipliers. The delayed installation of Helix by the GVI is partly due to failure of the initial batch of Burle channel multipliers to perform as expected. A number of the channel multipliers designed for Noblesse by Burle have also failed upon baking. Burle has now refined the design of these and we have installed two of the new multipliers and are assessing their performance. The remaining multipliers Will be upgraded to the new design from Burle once we confirm that the problem has been fixed.

Hohenberg, Charles M.↗
NASA NTRS2005

STS-114: Discovery Day 5 Post MMT Briefing

Wayne Hill, Space Shuttle Deputy Program Manager, and Chair of the Mission Management Team, reports the following: the testing of the thermal protection system in space, on orbit was successful; the MMT meeting formally approved the mission extension for one day; image analysis from the launch phase has been completed; tile and blankets had been formally cleared by the Engineering team; additional inspection of the reinforced carbon-carbon (RCC); gap filler, heat shield and small black spot phenomenon are carefully inspected and evaluated to prepare the safe return of the Discovery. Bill Gerstenmaier, ISS Program Manager reports on the extra vehicular activities (EVA): replaced the GPS antenna; prepared the airlock to attach the ESP2; re-powered CMG2; transfer of CWCs; and the MISSE packages were wrapped around thru at the end of the air lock. He mentioned the high currents problem seen on CMG3, which they will have to take off line to check and understand the problem. Consumables, engineering performance of the three sensors (LCS, LDRI, ITVC), CMG removal and replacement, EVA2 and EVA3, gap fillers, RCC, hydrogen tank pre-press cycles, thermal protection system, inspection, ISS supply maintenance, and projection of next flight are topics covered with the News Media.

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NASA NTRS2005

Mars Aerocapture and Validation of Mars-GRAM with TES Data

Mars Global Reference Atmospheric Model (Mars-GRAM) is a widely-used engineering- level Mars atmospheric model. Applications include systems design, performance analysis, and operations planning for aerobraking, entry descent and landing, and aerocapture. Typical Mars aerocapture periapsis altitudes (for systems with rigid-aeroshell heat shields) are about 50 km. This altitude is above the 0-40 km height range covered by Mars Global Surveyor Thermal Emission Spectrometer (TES) nadir observations. Recently, TES limb sounding data have been made available, spanning more than two Mars years (more than 200,000 data profiles) with altitude coverage up to about 60 km, well within the height range of interest for aerocapture. Results are presented comparing Mars-GRAM atmospheric density with densities from TES nadir and limb sounding observations. A new Mars-GRAM feature is described which allows individual TES nadir or limb profiles to be extracted from the large TES databases, and to be used as an optional replacement for standard Mars-GRAM background (climatology) conditions. For Monte-Carlo applications such as aerocapture guidance and control studies, Mars-GRAM perturbations are available using these TES profile background conditions.

Justus, C. G.↗
NASA NTRS2006

Mechanical Properties of T650-35/AFR-PE-4 at Elevated Temperatures for Lightweight Aeroshell Designs

Considerable efforts have been underway to develop multidisciplinary technologies for aeroshell structures that will significantly increase the allowable working temperature for the aeroshell components, and enable the system to operate at higher temperatures while sustaining performance and durability. As part of these efforts, high temperature polymer matrix composites and fabrication technologies are being developed for the primary load bearing structure (heat shield) of the spacecraft. New high-temperature resins and composite material manufacturing techniques are available that have the potential to significantly improve current aeroshell design. In order to qualify a polymer matrix composite (PMC) material as a candidate aeroshell structural material, its performance must be evaluated under realistic environments. Thus, verification testing of lightweight PMC's at aeroshell entry temperatures is needed to ensure that they will perform successfully in high-temperature environments. Towards this end, a test program was developed to characterize the mechanical properties of two candidate material systems, T650-35/AFR-PE-4 and T650-35/RP46. The two candidate high-temperature polyimide resins, AFR-PE-4 and RP46, were developed at the Air Force Research Laboratory and NASA Langley Research Center, respectively. This paper presents experimental methods, strength, and stiffness data of the T650-35/AFR-PE-4 material as a function of elevated temperatures. The properties determined during the research test program herein, included tensile strength, tensile stiffness, Poisson s ratio, compressive strength, compressive stiffness, shear modulus, and shear strength. Unidirectional laminates, a cross-ply laminate and two eight-harness satin (8HS)-weave laminates (4-ply and 10-ply) were tested according to ASTM standard methods at room and elevated temperatures (23, 316, and 343 C). All of the relevant test methods and data reduction schemes are outlined along with mechanical data. These data contribute to a database of material properties for high-temperature polyimide composites that will be used to identify the material characteristics of potential candidate materials for aeroshell structure applications.

Whitley, Karen S.↗
NASA NTRS2005

Passive Stability on an Entry Vehicle to Enhance Crew Survival

The most desirable crew survival feature for an entry vehicle is probably a full coverage escape system. With full coverage escape, crew survival is maintained for a wide range of failures by the allowing the crew to escape from the failed vehicle and performing the entry to touchdown flight phase in an alternative system. However, there are considerable challenges in providing a separate entry capability, and for some programs, requiring full coverage escape could result in program cancellation. An alternative means of providing for crew survival if the flight control system fails is to design a return vehicle that can enter without active attitude control. A study was performed to assess the feasibility of performing a totally passive entry. Lift over drag has a major impact on performing a passive entry, so a parametric of three typical lift over drag concepts was performed. First an assessment of historical entry vehicles was completed. Second an assessment of end of mission entry trajectories and entry trajectories initiated from ascent abort profiles were made. Trajectories for a wide array of pitch, yaw, and roll rates were made. Third, six-degree-of freedom analyses of the entry were performed. FOP a truly passive return, the entry vehicle must trim in only the heat shield forward orientation. An assessment of the effect of center of gravity placement to achieve this orientation was made.

Deger, Daniel J.↗
NASA NTRS2006

Adjoint Sensitivity Computations for an Embedded-Boundary Cartesian Mesh Method and CAD Geometry

Cartesian-mesh methods are perhaps the most promising approach for addressing the issues of flow solution automation for aerodynamic design problems. In these methods, the discretization of the wetted surface is decoupled from that of the volume mesh. This not only enables fast and robust mesh generation for geometry of arbitrary complexity, but also facilitates access to geometry modeling and manipulation using parametric Computer-Aided Design (CAD) tools. Our goal is to combine the automation capabilities of Cartesian methods with an eficient computation of design sensitivities. We address this issue using the adjoint method, where the computational cost of the design sensitivities, or objective function gradients, is esseutially indepeudent of the number of design variables. In previous work, we presented an accurate and efficient algorithm for the solution of the adjoint Euler equations discretized on Cartesian meshes with embedded, cut-cell boundaries. Novel aspects of the algorithm included the computation of surface shape sensitivities for triangulations based on parametric-CAD models and the linearization of the coupling between the surface triangulation and the cut-cells. The objective of the present work is to extend our adjoint formulation to problems involving general shape changes. Central to this development is the computation of volume-mesh sensitivities to obtain a reliable approximation of the objective finction gradient. Motivated by the success of mesh-perturbation schemes commonly used in body-fitted unstructured formulations, we propose an approach based on a local linearization of a mesh-perturbation scheme similar to the spring analogy. This approach circumvents most of the difficulties that arise due to non-smooth changes in the cut-cell layer as the boundary shape evolves and provides a consistent approximation tot he exact gradient of the discretized abjective function. A detailed gradient accurace study is presented to verify our approach. Thereafter, we focus on a shape optimization problem for an Apollo-like reentry capsule. The optimization seeks to enhance the lift-to-drag ratio of the capsule by modifyjing the shape of its heat-shield in conjunction with a center-of-gravity (c.g.) offset. This multipoint and multi-objective optimization problem is used to demonstrate the overall effectiveness of the Cartesian adjoint method for addressing the issues of complex aerodynamic design. This abstract presents only a brief outline of the numerical method and results; full details will be given in the final paper.

Nemec, Marian↗
NASA NTRS2006

Reentry-Vehicle Shape Optimization Using a Cartesian Adjoint Method and CAD Geometry

A DJOINT solutions of the governing flow equations are becoming increasingly important for the development of efficient analysis and optimization algorithms. A well-known use of the adjoint method is gradient-based shape. Given an objective function that defines some measure of performance, such as the lift and drag functionals, its gradient is computed at a cost that is essentially independent of the number of design variables (e.g., geometric parameters that control the shape). Classic aerodynamic applications of gradient-based optimization include the design of cruise configurations for transonic and supersonic flow, as well as the design of high-lift systems. are perhaps the most promising approach for addressing the issues of flow solution automation for aerodynamic design problems. In these methods, the discretization of the wetted surface is decoupled from that of the volume mesh. This not only enables fast and robust mesh generation for geometry of arbitrary complexity, but also facilitates access to geometry modeling and manipulation using parametric computer-aided design (CAD). In previous work on Cartesian adjoint solvers, Melvin et al. developed an adjoint formulation for the TRANAIR code, which is based on the full-potential equation with viscous corrections. More recently, Dadone and Grossman presented an adjoint formulation for the two-dimensional Euler equations using a ghost-cell method to enforce the wall boundary conditions. In Refs. 18 and 19, we presented an accurate and efficient algorithm for the solution of the adjoint Euler equations discretized on Cartesian meshes with embedded, cut-cell boundaries. Novel aspects of the algorithm were the computation of surface shape sensitivities for triangulations based on parametric-CAD models and the linearization of the coupling between the surface triangulation and the cut-cells. The accuracy of the gradient computation was verified using several three-dimensional test cases, which included design variables such as the free stream parameters and the planform shape of an isolated wing. The objective of the present work is to extend our adjoint formulation to problems involving general shape changes. Factors under consideration include the computation of mesh sensitivities that provide a reliable approximation of the objective function gradient, as well as the computation of surface shape sensitivities based on a direct-CAD interface. We present detailed gradient verification studies and then focus on a shape optimization problem for an Apollo-like reentry vehicle. The goal of the optimization is to enhance the lift-to-drag ratio of the capsule by modifying the shape of its heat-shield in conjunction with a center-of-gravity (c.g.) offset. This multipoint and multi-objective optimization problem is used to demonstrate the overall effectiveness of the Cartesian adjoint method for addressing the issues of complex aerodynamic design.

Nemec, Marian↗
NASA NTRS2006

STS-121/Discovery: Imagery Quick-Look Briefing

Kyle Herring (NASA Public Affairs) introduced Wayne Hale (Space Shuttle Program Manager) who stated that the imagery for the Space shuttle external tank showed the tank performed very well. Image analysis showed small pieces of foam falling off the rocket booster and external tank. There was no risk involved in these minor incidents. Statistical models were built to assist in risk analysis. The orbiter performed excellently. Wayne also provided some close-up pictures of small pieces of foam separating from the external tank during launching. He said the crew will also perform a 100% inspection of the heat shield. This flight showed great improvement over previous flights.

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NASA NTRS1995

Investigation of Possible Electromagnetic Disturbances caused by Spacecraft-Plasma Interactions at 4 Radii

The proposed Small Solar Probe mission features a close approach to the sun with a perihelion of 4 radii. Carbon molecules emitted from the spacecraft's heat shield will become ionized by electron impact and photoionization. The newly created ions and electrons may generate electromagnetic and electrostatic plasma waves which are possible sources of interference with in-situ plasma measurements.

computer simulations↗
NASA NTRS2006

Solid Modeling of Crew Exploration Vehicle Structure Concepts for Mass Optimization

Parametric solid and surface models of the crew exploration vehicle (CEV) command module (CM) structure concepts are developed for rapid finite element analyses, structural sizing and estimation of optimal structural mass. The effects of the structural configuration and critical design parameters on the stress distribution are visualized, examined to arrive at an efficient design. The CM structural components consisted of the outer heat shield, inner pressurized crew cabin, ring bulkhead and spars. For this study only the internal cabin pressure load case is considered. Component stress, deflection, margins of safety and mass are used as design goodness criteria. The design scenario is explored by changing the component thickness parameters and materials until an acceptable design is achieved. Aluminum alloy, titanium alloy and an advanced composite material properties are considered for the stress analysis and the results are compared as a part of lessons learned and to build up a structural component sizing knowledge base for the future CEV technology support. This independent structural analysis and the design scenario based optimization process may also facilitate better CM structural definition and rapid prototyping.

Mukhopadhyay, Vivek↗
NASA NTRS2006

Integrated Thermal Protection Systems and Heat Resistant Structures

In the early stages of NASA's Exploration Initiative, Snecma Propulsion Solide was funded under the Exploration Systems Research & Technology program to develop a CMC heatshield, a deployable decelerator, and an ablative heat shield for reentry vehicles. Due to changes within NASA's Exploration Initiative, this task was cancelled in early FY06. This paper will give an overview of the work that was accomplished prior to cancellation. The Snecma team consisted of MT Aerospace, Germany, and Materials Research & Design (MR&D), NASA Langley, NASA Dryden, and NASA Ames in the United States. An Apollo-type capsule was chosen as the reference vehicle for the work. NASA Langley generated the trajectory and aerothermal loads. Snecma and MT Aerospace began the design of a ceramic aft heatshield (CAS) utilizing C/SiC panels as the capsule heatshield. MR&D led the design of a C/SiC deployable decelerator, NASA Ames led the characterization of several ablators, NASA Dryden led the development of a heath management system and the high temperature structures testing, and NASA Langley led the insulation characterization. Though the task was pre-maturely cancelled, a significant quantity of work was accomplished.

Pichon, Thierry↗