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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Critical Technologies for Hypersonic Vehicle Development

The objective of the present RTO/VKI Lecture Series is to focus attention on the technologies that play a critical role in hypersonic vehicle development. Owing to the demanding flight environment, successful development of hypersonic vehicles will require progress in understanding and surmounting specific technical problems in ground test, numerical simulation and flight test. Following the introductory remarks stating the objectives of the Lecture Series, a historical perspective on hypersonic vehicle development was given to establish the context and to highlight the emerging role of numerical simulation in vehicle design. A thorough review of ongoing vehicle development and flight-test programs completed the introductory portion. To provide sufficient background information, lectures were presented on compressible flows of perfect and imperfect gases, with special attention given to shock-wave boundary-layer interactions, laminar to turbulent transition, and high temperature gas properties. Advancements in computational modeling capabilities for hypersonic vehicle design were addressed, and the ongoing need for validation data, as well as a consistent validation methodology, where highlighted. Specific critical technology areas, including trajectory aerothermal environment definition, system trade studies, propulsion systems, aerodynamic control laws, flight instrumentation, thermal protection systems and flight experiments were all addressed in separate lectures given by international experts. Finally, the potential of plasma devices to ameliorate or avoid critical aerothermal phenomena was presented, providing a good example of the type of creative effort required for achieving progress. In all of the presentations the needs of future hypersonic flight vehicle development programs were addressed.

Research and Technology Organisation (RTO)↗
NASA NTRS2007

The Columbia Accident Investigation and The NASA Glenn Ballistic Impact Laboratory Contributions Supporting NASA's Return to Flight

On February 1, 2003, the Space Shuttle Columbia broke apart during reentry, resulting in loss of the vehicle and its seven crewmembers. For the next several months, an extensive investigation of the accident ensued involving a nationwide team of experts from NASA, industry, and academia, spanning dozens of technical disciplines. The Columbia Accident Investigation Board (CAIB), a group of experts assembled to conduct an investigation independent of NASA, concluded in August, 2003 that the most likely cause of the loss of Columbia and its crew was a breach in the left wing leading edge Reinforced Carbon-Carbon (RCC) thermal protection system initiated by the impact of thermal insulating foam that had separated from the orbiters external fuel tank 81 seconds into the mission's launch. During reentry, this breach allowed superheated air to penetrate behind the leading edge and erode the aluminum structure of left wing, which ultimately led to the breakup of the orbiter. The findings of the CAIB were supported by ballistic impact tests, which simulated the physics of External Tank Foam impact on the RCC wing leading edge material. These tests ranged from fundamental material characterization tests to full-scale Orbiter Wing Leading Edge tests. Following the accident investigation, NASA spent the next 18 months focused on returning the shuttle safely to flight. In order to fully evaluate all potential impact threats from the many debris sources on the Space Shuttle during ascent, NASA instituted a significant impact testing program. The results from these tests led to the validation of high-fidelity computer models, capable of predicting actual or potential Shuttle impact events, were used in the certification of STS-114, NASA s Return to Flight Mission, as safe to fly. This presentation will provide a look into the inner workings of the Space Shuttle and a behind the scenes perspective on the impact analysis and testing done for the Columbia Accident Investigation and NASA's Return to Flight programs. In addition, highlights from recent Shuttle missions are presented.

Melis, Matthew E.↗
NASA NTRS2017

Thermal Protection Supplement for Reducing Interface Thermal Mismatch

A thermal protection system that reduces a mismatch of thermal expansion coefficients CTE between a first material layer (CTE1) and a second material layer (CTE2) at a first layer-second layer interface. A portion of aluminum borosilicate (abs) or another suitable additive (add), whose CTE value, CTE(add), satisfies (CTE(add)-CTE1)(CTE(add)-CTE2)<0, is distributed with variable additive density,.rho.(z;add), in the first material layer and/or in the second material layer, with.rho.(z;add) near the materials interface being relatively high (alternatively, relatively low) and.rho.(z;add) in a region spaced apart from the interface being relatively low (alternatively, relatively high).

Stewart, David A.↗
NASA NTRS1972

A Numerical Analysis of the Transient Response of an Ablation System Including Effects of Thermal Nonequilibrium, Mass Transfer and Chemical Kinetics

The differential equations governing the transient response of a one-dimensional ablative thermal protection system undergoing stagnation ablation are derived. These equations are for thermal nonequilibrium effects between the pyrolysis gases and the char layer and kinetically controlled chemical reactions and mass transfer between the pyrolysis gases and the char layer. The boundary conditions are written for the particular case of stagnation heating with surface removal by oxidation or sublimation and pyrolysis of the uncharred layer occurring in a plane. The governing equations and boundary conditions are solved numerically using the modified implicit method (Crank-Nicolson method). Numerical results are compared with exact solutions for a number of simplified cases. The comparison is favorable in each instance.

Clark, R. K.↗
NASA NTRS2012

SPRITE: A TPS Test Bed for Ground and Flight

Engineers in the Entry Systems and Technology Division at NASA Ames Research Center developed a fully instrumented, small atmospheric entry probe called SPRITE (Small Probe Reentry Investigation for TPS Engineering). SPRITE, conceived as a flight test bed for thermal protection materials, was tested at full scale in an arc-jet facility so that the aerothermal environments the probe experiences over portions of its flight trajectory and in the arc-jet are similar. This ground-to-flight traceability enhances the ability of mission designers to evaluate margins needed in the design of thermal protection systems (TPS) of larger scale atmospheric entry vehicles. SPRITE is a 14-inch diameter, 45 deg. sphere-cone with a conical aftbody and designed for testing in the NASA Ames Aerodynamic Heating Facility (AHF). The probe is a two-part aluminum shell with PICA (phenolic impregnated carbon ablator) bonded on the forebody and LI-2200 (Shuttle tile material) bonded to the aftbody. Plugs with embedded thermocouples, similar to those installed in the heat shield of the Mars Science Laboratory (MSL), and a number of distributed sensors are integrated into the design. The data from these sensors are fed to an innovative, custom-designed data acquisition system also integrated with the test article. Two identical SPRITE models were built and successfully tested in late 2010-early 2011, and the concept is currently being modified to enable testing of conformable and/or flexible materials.

Ablation↗
NASA NTRS2019

Orion Heat Shield Manufacturing Producibility Improvements for the EM-1 Flight Test Program

This paper describes how the Orion program is incorporating improvements in the heat shield design and manufacturing processes reducing programmatic risk and ensuring crew safety in support of NASA’s Exploration Missions. The Orion program successfully completed the EFT-1 flight test in 2014 and is currently developing the EM-1 spacecraft to meet the test objectives of an orbital mission to the moon and return to earth in 2019. Lessons learned from the EFT-1 manufacturing and flight test experience are being incorporated into a wide variety of vehicle systems and manufacturing processes to reduce risk to the Orion missions and flight crew. A critical contributor to crew safety is the heat shield that protects the crew capsule during re-entry through the earth’s atmosphere for return from deep space. The first flight test vehicle, EFT-1, was manufactured and tested in the Neil Armstrong Operations and Checkout (O&C) facility at KSC to demonstrate early risk reduction including the functionality of the Thermal Protection Systems (TPS) for capsule safe return to earth. The approach for the EFT-1 heat shield utilized a low risk approach using Apollo heritage design and manufacturing processes using an Avcoat TPS ablator with a honeycomb substrate to provide a one piece heat shield to meet the mission re-entry heating environments. The manufacturing processes used honeycomb cell injection guns which were redeveloped from the Apollo Lunar Program processes to build the EFT-1 heat shield. The completed heat shield was transported across the country by aircraft to the O&C at KSC for installation onto the capsule. The EFT-1 heat shield successfully performed its mission and experienced ~80% of the re-entry velocity (50% heating rate) for a lunar return for an Exploration Mission. The second flight test vehicle is the EM-1 mission which will have additional flight systems installed to fly to the moon and return. Heat shield design and producibility improvements have been incorporated in the EM-1 vehicle to meet deep space mission and programmatic requirements. The design continues to use the Avcoat material, but in a “block” configuration to enable improvements in the application processes as well as additional improvements in the carrier structure design and manufacturing operations. Incorporating flight test results and producibility improvements from EFT-1 for the heat shield system design and processes have improved the thermal protection capability, improved the producibility, and cost for EM-1 flight test.

Producibility↗
NASA NTRS2020

TPS and Entry Technologies for Future Outer Planet Exploration

The lack of knowledge about the Ice Giants (Voyager being the only probe to briefly visit them) and literally narrow window of planetary alignment for pragmatic missions to the Ice Giants, make them high priority targets in the next decade. The purpose of this white paper is to provide an overview to the NRC Decadal Survey on thermal protection system (TPS) technologies required for future Outer Planet exploration missions. A prime conclusion is that several of the most significant recommendations made during the last decadal survey were addressed positioning the TPS community to better support missions to the Outer Planets. These include maturation of the Heatshield for Extreme Entry Environment Technology (HEEET) to TRL 6 as replacement for Carbon Phenolic (that requires requalification itself), TPS test facility upgrades, and design tool improvements. These new materials and test methods are enabling for Outer Planet missions. However, there are limitations in the HEEET technology and available ground based test facilities that could become mission constraints depending on the science objectives. This white paper discusses opportunities to mitigate those constraints. In addition, if a mission is not scheduled in the near future, these new developments are at risk of becoming unavailable. Therefore, we recommend that NASA invest in a cross-cutting technology program that focuses on sustainment of relevant TPS materials, entry systems, test facilities, design tools, and flight instrumentation.

Outer Planets↗
NASA NTRS2013

Comparison of Failure Modes in 2-D and 3-D Woven Carbon Phenolic Systems

NASA Ames Research Center is developing Woven Thermal Protection System (WTPS) materials as a new class of heatshields for entry vehicles (Stackpoole). Currently, there are few options for ablative entry heatshield materials, none of which is ideally suited to the planetary probe missions currently of interest to NASA. While carbon phenolic was successfully used for the missions Pioneer Venus and Galileo (to Jupiter), the heritage constituents are no longer available. An alternate carbon phenolic would need to be qualified for probe missions, which is most efficient at heat fluxes greater than those currently of interest. Additional TPS materials such as Avcoat and PICA are not sufficiently robust for the heat fluxes required. As a result, there is a large TPS gap between the materials efficient at very high conditions (carbon phenolic) and those that are effective at low-moderate conditions (all others). Development of 3D Woven TPS is intended to fill this gap, targeting mid-density weaves that could with withstand mid-range heat fluxes between 1100 W/sq cm and 8000 W/sq cm (Venkatapathy (2012). Preliminary experimental studies have been performed to show the feasibility of WTPS as a future mid-range TPS material. One study performed in the mARC Jet Facility at NASA Ames Research Center characterized the performance of a 3D Woven TPS sample and compared it to 2D carbon phenolic samples at ply angles of 0deg, 23.5deg, and 90deg. Each sample contained similar compositions of phenolic and carbon fiber volume fractions for experimental consistency. The goal of this study was to compare the performance of the TPS materials by evaluating resulting recession and failure modes. After exposing both samples to similar heat flux and pressure conditions, the 2D carbon phenolic laminate was shown to experience significant delamination between layers and further pocketing underneath separated layers. The 3D Woven TPS sample did not experience the delamination or pocketing failure modes because z-fibers in the through-thickness direction provided extra reinforcement to hold material layers together. Therefore, the benefit of using a 3D weave architecture was shown to alleviate failure modes experienced by a 2D laminate sample of similar material composition. In summary this poster reviews the thermal response performance comparisons drawn between a 3D Woven TPS sample and 2D Carbon Phenolic samples after performing rigorous heating experiments in the mARC facility at NASA Ames. Although the mARC Facility is still in its developmental stages, researchers expect similar trends in failure modes observed from large scale arc jet facilities. This work helps demonstrate the viability of 3D Woven TPSs as a new TPS option for future atmospheric entry missions.

Rossman, Grant A.↗
NASA NTRS2019

Overview of Heatshield for Extreme Entry Environment Technology (HEEET)

The objective of the Heatshield for Extreme Entry Environment Technology (HEEET) projects is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. Destinations that have extreme entry environments with heat fluxes > 3500 W/cm2 and pressures up to 5 atmospheres, entry environments that NASA has not flown since Pioneer-Venus and Galileo. The scope of the project is broad and can be split into roughly four areas, Manufacturing/Integration, Structural Testing and Analysis, Thermal Testing and Analysis and Documentation. Manufacturing/Integration covers from raw materials, piece part fabrication to final integration on a 1-meter base diameter 45-degree sphere cone Engineering Test Unit (ETU). A key aspect of the project was to transfer as much of the manufacturing technology to industry in preparation to support future mission infusion. The forming, infusion and machining approaches were transferred to Fiber Materials Inc. and FMI then fabricated the piece parts from which the ETU was manufactured. The base 3D-woven material consists of a dual layer weave with a high-density outer layer to manage recession in the system and a lower density, lower thermal conductivity inner layer to manage the heat load. At the start of the project it was understood that due to weaving limitations the heat shield was going to be manufactured from a series of tiles. And it was recognized that the development of a seam solution that met the structural and thermal requirements of the system was going to be the most challenging aspect of the project. It was also recognized that the seam design would drive the final integration approach and therefore the integration of the ETU was kept in-house within NASA. A final seam concept has been successfully developed and implemented on the ETU. The structural testing and analysis covers from characterization of the different layers of the infused material as functions of weave direction and temperature to sub-component level testing such as 4pt bend testing at sub-ambient and elevated temperature and culminates in testing of the ETU results from which will validate the structural models developed using the element and sub-component level tests. Given the seam has to perform both structurally and aerothermally during entry a novel 4pt bend test fixture was developed allowing articles to be tested while the front surface is heated with a laser. These tests are being utilized to establish the systems structural capability during entry.A broad range of aerothermal tests (arcjet tests) were performed to develop material response models for predicting the required TPS thickness to meet a missions needs and to evaluate failure modes and establish the capability of the system. The final aspect of the project is to develop a comprehensive Design and Data Book such that a future mission will have the information necessary to adopt the technology. This presentation will provide an overview for each of these areas and argue that HEEET has successfully achieved TRL 6.

HEEET↗
DOE OSTI2023

Fracture‐Resistant and Thermally Insulating Ultrahigh‐Temperature Carbide Foams

Dense ultrahigh‐temperature ceramics (UHTCs) carbides are recognized as potential materials for thermal protection systems (TPS) owing to properties beyond existing structural materials’ capabilities. Recent advances in UHTCs have enabled the development of multiscale porous microstructures. Herein, it is highlighted that the porosity in UHTCs are no longer treated as a defect but as a functional property specifically tailored for thermal insulation. It is a promising solution to design and fabricate bulk UHTC foams via a freeze‐drying (FD) approach followed by calibrated pressureless spark plasma sintering. Herein, monolithic TaC and HfC UHTC foams and their composite show the partial solid–solution formation of (Ta, Hf)C with porosity ≥50%. TaC–HfC foam (≈80–92 N) shows an intermediate load‐bearing capability compared to monolithic TaC (≈120–135 N) and HfC (≈28–35 N) foams, with no evident cracking on the sample surface. The thermal conductivity of partial solid‐solution TaC–HfC foam increases up to fivefold compared to parent UHTC foams. In the results, solid solutions’ efficacy and pores’ unidirectionality in providing thermal insulation to TaC–HfC while maintaining its high‐load bearing capability are illustrated. In conclusion, the developed technique establishes a new paradigm shift in UHTCs, expanding their potential for TPS in extreme environments.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Mars 2020 Entry, Descent and Landing Instrumentation (MEDLI2)

This paper will introduce Mars Entry Descent and Landing Instrumentation (MEDLI2) on NASA's Mars2020 mission. Mars2020 is a flagship NASA mission with science and technology objectives to help answer questions about possibility of life on Mars as well as to demonstrate technologies for future human expedition. Mars2020 is scheduled for launch in 2020. MEDLI2 is a suite of instruments embedded in the heatshield and backshell thermal protection systems of Mars2020 entry vehicle. The objectives of MEDLI2 are to gather critical aerodynamics, aerothermodynamics and TPS performance data during EDL phase of the mission. MEDLI2 builds up the success of MEDLI flight instrumentation on Mars Science Laboratory mission in 2012. MEDLI instrumentation suite measured surface pressure and TPS temperature on the heatshield during MSL entry into Mars. MEDLI data has since been used for unprecedented reconstruction of aerodynamic drag, vehicle attitude, in-situ atmospheric density, aerothermal heating, transition to turbulence, in-depth TPS performance and TPS ablation. [1,2] In addition to validating predictive models, MEDLI data has highlighted extra margin available in the MSL forebody TPS, which can potentially be used to reduce vehicle parasitic mass. MEDLI2 expands the scope of instrumentation by focusing on quantities of interest not addressed in MEDLI suite. The type the sensors are expanded and their layout on the TPS modified to meet these new objectives. The paper will provide key motivation and governing requirements that drive the choice and the implementation of the new sensor suite. The implementation considerations of sensor selection, qualification, and demonstration of minimal risk to the host mission will be described. The additional challenges associated with mechanical accommodation, electrical impact, data storage and retrieval for MEDLI2 system, which extends sensors to backshell will also be described.

Thermal Protection System↗
NASA NTRS2020

Technologies for Future Venus Exploration

The purpose of this white paper is to provide an overview to the NRC Decadal Survey Inner Planets Sub-Panel on thermal protection system (TPS) technologies required for future Venus exploration missions. It considers the capability of heritage TPS technology used by the Pioneer Venus and Galileo probe missions and identifies new technologies that could enable greater science value and more ambitious missions in the future. A prime conclusion is that there are important advances regarding the availability of forebody TPS required for Venus entry probes. Specifically, the carbon phenolic flown on the Pioneer Venus probes has been deemphasized and a new 3D woven material system, Heatshield for Extreme Entry Environment Technology (HEEET) has replaced carbon phenolic. Along with the development of HEEET, there have been test facility upgrades and design tool improvements. These new material and test methods are enabling for Venus missions. However, without a mission scheduled in the near future, even these new developments are at risk of becoming unavailable. Therefore, we recommend that NASA invest in a cross-cutting technology program that focuses on sustainment of relevant TPS materials, entry systems, test facilities, design tools, and flight instrumentation.

Thermal Protection Systems↗
NASA NTRS2010

Multidimensional Tests of Thermal Protection Materials in the Arcjet Test Facility

Many thermal protection system materials used for spacecraft heatshields have anisotropic thermal properties, causing them to display significantly different thermal characteristics in different directions, when subjected to a heating environment during flight or arcjet tests. This paper investigates the effects of sidewall heating coupled with anisotropic thermal properties of thermal protection materials in the arcjet environment. Phenolic Impregnated Carbon Ablator (PICA) and LI-2200 materials (the insulation material of Shuttle tiles) were used for this study. First, conduction-based thermal response simulations were carried out, using the Marc.Mentat finite element solver, to study the effects of sidewall heating on PICA arcjet coupons. The simulation showed that sidewall heating plays a significant role in thermal response of these models. Arcjet tests at the Aerodynamic Heating Facility (AHF) at NASA Ames Research Center were performed later on instrumented coupons to obtain temperature history at sidewall and various radial locations. The details of instrumentation and experimental technique are the prime focus of this paper. The results obtained from testing confirmed that sidewall heating plays a significant role in thermal response of these models. The test results were later used to verify the two-dimensional ablation, thermal response, and sizing program, TITAN. The test data and model predictions were found to be in excellent agreement

Agrawal, Parul↗
NASA NTRS1973

Investigation of high temperature antennas for space shuttle

The design and development of high temperature antennas for the space shuttle orbiter are discussed. The antenna designs were based on three antenna types, an annular slot (L-Band), a linear slot (C-Band), and a horn (C-Band). The design approach was based on combining an RF window, which provides thermal protection, with an off-the-shelf antenna. Available antenna window materials were reviewed and compared, and the materials most compatible with the design requirements were selected. Two antenna window design approaches were considered: one employed a high temperature dielectric material and a low density insulation material, and the other an insulation material usable for the orbiter thermal protection system. Preliminary designs were formulated and integrated into the orbiter structure. Simple electrical models, with a series of window configurations, were constructed and tested. The results of tests and analyses for the final antenna system designs are given and show that high temperature antenna systems consisting of off-the-shelf antennas thermally protected by RF windows can be designed for the Space Shuttle Orbiter.

Kuhlman, E. A.↗
NASA NTRS2010

Multidimensional Testing of Thermal Protection Materials in the Arcjet Test Facility

Many thermal protection system materials used for spacecraft heatshields have anisotropic thermal properties, causing them to display significantly different thermal characteristics in different directions, when subjected to a heating environment during flight or arcjet tests. The anisotropic effects are enhanced in the presence of sidewall heating. This paper investigates the effects of anisotropic thermal properties of thermal protection materials coupled with sidewall heating in the arcjet environment. Phenolic Impregnated Carbon Ablator (PICA) and LI-2200 materials (the insulation material of Shuttle tiles) were used for this study. First, conduction-based thermal response simulations were carried out, using the Marc.Mentat finite element solver, to study the effects of sidewall heating on PICA arcjet coupons. The simulation showed that sidewall heating plays a significant role in thermal response of these models. Arcjet tests at the Aerodynamic Heating Facility (AHF) at NASA Ames Research Center were performed later on instrumented coupons to obtain temperature history at sidewall and various radial locations. The details of instrumentation and experimental technique are the prime focus of this paper. The results obtained from testing confirmed that sidewall heating plays a significant role in thermal response of these models. The test results were later used to validate the two-dimensional ablation, thermal response, and sizing program, TITAN. The test data and model predictions were found to be in excellent agreement

Agrawal, Parul↗
NASA NTRSDate not supplied

Parametric Analysis of Entry Vehicles for Giant Planet Missions

Summarize concept designs for entry vehicles for giant planet destinations identified as high priority in the latest decadal survey. Identify viable entry states, aerothermal environments, and heatshield thermal protection systems (TPS) for various vehicle dimensions. Viable TPS options and sizing focus on low-g (< 50g) entry conditions to avoid costly instrumentation requalification. TPS manufacturing capabilities are also taken into consideration while adhering to the manufacturing capabilities of the TPS options. Margined mass estimates for heatshield TPS options are provided for Uranus and Saturn test cases.

Giant Planet↗
NASA NTRSDate not supplied

TPS and Entry Systems Technologies for Future Mars and Titan Exploration

During the past twenty years, NASA effectively erased earlier Mars mishaps with six successful missions to the Red Planet. These missions delivered one orbiter and five payloads to the surface. Those payloads included three rovers, Spirit (2004) which roamed 11 years, Opportunity (2004) which roamed nearly 15 years, and Curiosity (2012) which is in its ninth year, along with two landers, Phoenix (2008) and InSIGHT (2018). In July, the Mars 2020 mission will send another large rover, Perseverance, which will land in 2021. The InSIGHT mission even demonstrated the capability to send CubeSats along to help with communication back to the surface. NASA has demonstrated the capability to land a metric ton of vehicles plus science instruments on Mars and expects that the same technologies will be equally successful landing Dragonfly on Titan in the 2030’s. The thermal protection systems (TPS) used on the Mars missions are sufficiently developed and matured to continue furthering science on both Mars and Titan, assuming that the TPS materials are sustained by industry. The purpose of this white paper is to encourage further exploration and science on both Mars and Titan because we have the technologies to support them. In addition, we will look forward to human exploration of Mars and identify the improvements in TPS materials required to facilitate landing the larger payloads.

Thermal Protection Systems↗
NASA NTRS1980

Heat conduction in three dimensions

Multidimensional heat conduction program computes transient temperature history and steady state temperatures of complex body geometries in three dimensions. Emphasis is placed on type of problems associated with Space Shuttle thermal protection system, but program could be used in thermal analysis of most three dimensional systems.

Danza, T. M.↗