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NASA NTRSDate not supplied

Three Dimensionally Woven Mid-Density Carbon Phenolic (3MDCP) is a Novel Single Piece Ablative TPS for Extreme Entry Environments

Three Dimensionally Woven Mid-Density Carbon Phenolic (3MDCP) is robust, single piece, carbon phenolic ablative thermal protection system under development at NASA Ames Research Center initially for the Mars Sample Return Earth Entry System (MSR EES). The MSR EES requirements drove the need for TPS with no seams, capable of surviving the highest entry conditions for any NASA Earth return capsule with heat fluxes >2000 W/cm2 and pressures >1.5 atmospheres. To produce 3MDCP required development of new weaving infrastructure to enable weaving of preforms large enough to form into a single piece heatshield. It required development of forming techniques to transform a flat woven panel into a sphere cone shape and enhanced infusion processes to support larger scale infusion of resin into the formed preforms. A rigorous performance testing campaign was conducted to develop and validate the materials thermal response model used to determine the required material thickness and to demonstrate the material can survive the extreme entry conditions. The end of the development effort (end of FY26) will result in a TPS at Technical Readiness Level (TRL) 6 and Manufacturing Readiness Level (MRL) 6+ for the MSR EES mission and a mature system ready to support other missions. This poster will provide a snapshot of where 3MDCP is in its development phase.

Ablator↗

NASA NTRSDate not supplied

Impact of NASA’s Entry Systems Modeling Project on Planetary Mission Design

Planetary missions continue to grow larger and more complex. Furthermore, the current focus on human exploration of the Moon and Mars, as well as Mars Sample Return(MSR), place increas-ingly stringent requirements on the reliability of the entry, descent, and landing (EDL) system that ensures the safe delivery of payload or crew to their destination. Planetary EDL is an area in which mission designers are critically reliant on modeling and simulation to demonstrate the reliability of the system, as there are no ground facilities that are able to fully test these systems in a flight-relevant environment. NASA’s state-of-the-art modeling and simulation capability must continually evolve to meet the needs of the next generation of planetary EDL. To accomplish this aim, NASA’s Entry Systems Modeling (ESM) Project was formed in 2013and is funded bythe Space Technology Mission Directorate(STMD) and Science Mission Directorate (SMD). ESM is the Agency’s only cross-cutting effort for advancing entry systems modeling and simulation capabilities across a range of technical disciplines and Solar System destinations. ESM is a portfolio project covering a variety of mid-TRL research efforts within four core EDL-related areas of investment: (1) Thermal protection material modeling, (2) Shock layer kinetics and radiation, (3) Aerosciences, and (4) Guidance, navigation, and con-trol. The material modeling group creates detailed material response modelsof thermal protection systems (TPS)from the micro to macro scale, and at the fun-damental and engineering levels. Shock layer kinetics and radiation focuses on radiative heating of space-craft, quantum chemistry and benchmark experiments for validation.Aerosciences is a broad research area that impacts many aspects of entry systems, including parachutes, aerodynamics, and turbulent heating augmentation due to TPS roughness.The guidance, navigation,and control effort under ESM is expanding the capabilities of NASA’s main flight mechanics tool, POST2, for use on high-performance computing architectures and to generalize interoperability with external applications for more detailed end-to-end simula-tion.In addition, several focusedresearch topics have been approvedto augment ESM’s core portfolio. These include efforts for deep post-flight analysis of Mars 2020/MEDLI2 flight data; development ofTPS failure models; improvement of hypersonic wakeflow models; and a recently concluded effort to provide material response models for NuSil-coated PICA heat-shield material. This presentation will discuss each of these investment areas and demonstrate via real mission examples how advances to the state-of-the-art enabled by ESM are directly impacting the missions of today and tomorrow, including InSight, Mars 2020, Mars Sample Return, Orion, and Dragonfly.

Entry Systems Modeling↗

DOE OSTI2022

High-Temperature Creep Test Suite for Grizzly

A recent development in the Grizzly has focused on improving its ability to model the high-temperature response of alloys, enabling its use for predictive modeling of material response for advanced reactor applications. This report documents an effort to expand the example and assessment test suites in Grizzly to include a set of problems that exercise the models for high-temperature response of components relevant to advanced reactors. These problems can be used to assess the accuracy of models, provide examples for users interested in modeling this class of problems, monitoring performance on large-scale problems and as test cases for future feature development.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Micromechanical simulation of damage progression in carbon phenolic composites

Carbon/phenolic composites are used extensively as ablative insulating materials in the nozzle region of solid rocket motors. The current solid rocket motor (RSRM) on the space shuttle is fabricated from woven rayon cloth which is carbonized and then impregnated with the phenolic resin. These plies are layed up in the desired configuration and cured to form the finished part. During firing, the surface of the carbon/phenolic insulation is exposed to 5000 F gases from the rocket exhaust. The resin pyrolizes and the material chars to a depth which progresses with time. The rate of charring and erosion are generally predictable, and the insulation depth is designed to allow adequate safety margins over the firing time of the motor. However, anomalies in the properties and response of the carbon/phenolic materials can lead to severe material damage which may decrease safety margins to unacceptable levels. Three macro damage modes which were observed in fired nozzles are: ply lift, 'wedge out', and pocketing erosion. Ply lift occurs in materials with plies oriented nearly parallel to the surface. The damage occurs in a region below the charred material where material temperatures are relatively low - about 500 F. Wedge out occurs at the intersection of nozzle components whose plies are oriented at about 45 deg. The corner of the block of material breaks off along a ply interface. Pocketing erosion occurs in material with plies oriented normal to the surface. Thermal expansion is restrained in two directions resulting in large tensile strains and material failure normal to the surface. When a large section of material is removed as a result of damage, the insulation thickness is reduced which may lead to failure of the nozzle due to excessive heating of critical components. If these damage events cannot be prevented with certainty, the designer must increase the thickness of the insulator thus adding to both weight and cost. One of the difficulties in developing a full understanding of these macro damage mechanisms is that the loading environment and the material response to that environment are extremely complex. These types of damage are usually only observed in actual motor firings. Therefore, it is difficult and expensive to evaluate the reliability of new materials. Standard material tests which measure mechanical and thermal properties of test specimens can only provide a partial picture of how the material will respond in the service environment. The development of the ANALOG test procedure which can combine high heating rates and mechanical loads on a specimen will improve the understanding of the interactive effects of the various loads on the system. But a mechanistic model of material response which can account for the heterogeneity of the material, the progression of various micromechanical damage mechanisms, and the interaction of mechanical and thermal stresses on the material is required to accurately correlate material tests with response to service environments. A model based on fundamental damage mechanisms which is calibrated and verified under a variety of loading conditions will provide a general tool for predicting the response of rocket nozzles. The development of a micromechanical simulation technique was initiated and demonstrated to be effective for studying across-ply tensile failure of carbon/phenolic composites.

Slattery, Kerry T.↗

NASA NTRS1989

A study of material damping in large space structures

A constitutive model was developed for predicting damping as a function of damage in continuous fiber reinforced laminated composites. The damage model is a continuum formulation, and uses internal state variables to quantify damage and its subsequent effect on material response. The model is sensitive to the stacking sequence of the laminate. Given appropriate baseline data from unidirectional material, and damping as a function of damage in one crossply laminate, damage can be predicted as a function of damage in other crossply laminates. Agreement between theory and experiment was quite good. A micromechanics model was also developed for examining the influence of damage on damping. This model explicitly includes crack surfaces. The model provides reasonable predictions of bending stiffness as a function of damage. Damping predictions are not in agreement with the experiment. This is thought to be a result of dissipation mechanisms such as friction, which are not presently included in the analysis.

Highsmith, A. L.↗

NASA NTRS2020

Toward an In-Depth Material Model for Cermet Nuclear Thermal Rocket Fuel Elements

The development and qualification of nuclear thermal propulsion (NTP) fuel element technologies would be aided by an in-depth model of material response and failure modes at operating conditions. Integrated computational materials engineering techniques have the potential to provide such a model, as demonstrated here through three case studies focused on a tungsten-uranium mononitride cermet fuel. The first case focuses on the erosion of tungsten (W, also named wolfram), a nominal coating/cladding material, in hot hydrogen. Ab initio techniques are used to calculate erosion rates and thermal expansion at NTP operating conditions. The second focuses on the stability of uranium mononitride (UN) fuels at high temperature and in the presence of hydrogen. Phase diagram techniques reveal potential instabilities and decomposition pathways at high hydrogen concentrations. The third focuses on using microstructure information to predict high temperature mechanical response and failure of tungsten, used in refractory cermet materials. Combined finite element and discrete dislocation dynamics techniques provide mechanical properties in agreement with experimental methods. The integration of these techniques for an all-encompassing material model is discussed.

cermet↗

NASA NTRS2014

The Inclusion of Arbitrary Load Histories in the Strength Decay Model for Stress Rupture

Stress rupture is a failure mechanism where failures can occur after a period of time, even though the material has seen no increase in load. Carbon/epoxy composite materials have demonstrated the stress rupture failure mechanism. In a previous work, a model was proposed for stress rupture of composite overwrap pressure vessels (COPVs) and similar composite structures based on strength degradation. However, the original model was limited to constant load periods (holds) at constant load. The model was expanded in this paper to address arbitrary loading histories and specifically the inclusions of ramp loadings up to holds and back down. The broadening of the model allows for failures on loading to be treated as any other failure that may occur during testing instead of having to be treated as a special case. The inclusion of ramps can also influence the length of the "safe period" following proof loading that was previously predicted by the model. No stress rupture failures are predicted in a safe period because time is required for strength to decay from above the proof level to the lower level of loading. Although the model can predict failures during the ramp periods, no closed-form solution for the failure times could be derived. Therefore, two suggested solution techniques were proposed. Finally, the model was used to design an experiment that could detect the difference between the strength decay model and a commonly used model for stress rupture. Although these types of models are necessary to help guide experiments for stress rupture, only experimental evidence will determine how well the model may predict actual material response. If the model can be shown to be accurate, current proof loading requirements may result in predicted safe periods as long as 10(13) years. COPVs design requirements for stress rupture may then be relaxed, allowing more efficient designs, while still maintaining an acceptable level of safety.

Reeder, James R.↗

NASA NTRS2015

Empirical Model Development for Predicting Shock Response on Composite Materials Subjected to Pyroshock Loading

The NASA Engineering and Safety Center (NESC) received a request to develop an analysis model based on both frequency response and wave propagation analyses for predicting shock response spectrum (SRS) on composite materials subjected to pyroshock loading. The model would account for near-field environment (approx. 9 inches from the source) dominated by direct wave propagation, mid-field environment (approx. 2 feet from the source) characterized by wave propagation and structural resonances, and far-field environment dominated by lower frequency bending waves in the structure. This report documents the outcome of the assessment.

Gentz, Steven J.↗

NASA NTRS2015

Empirical Model Development for Predicting Shock Response on Composite Materials Subjected to Pyroshock Loading

The NASA Engineering and Safety Center (NESC) received a request to develop an analysis model based on both frequency response and wave propagation analyses for predicting shock response spectrum (SRS) on composite materials subjected to pyroshock loading. The model would account for near-field environment (~9 inches from the source) dominated by direct wave propagation, mid-field environment (approximately 2 feet from the source) characterized by wave propagation and structural resonances, and far-field environment dominated by lower frequency bending waves in the structure. This document contains appendices to the Volume I report.

Gentz, Steven J.↗

NASA NTRS2012

Thermal Analysis of Small Re-Entry Probe

The Small Probe Reentry Investigation for TPS Engineering (SPRITE) concept was developed at NASA Ames Research Center to facilitate arc-jet testing of a fully instrumented prototype probe at flight scale. Besides demonstrating the feasibility of testing a flight-scale model and the capability of an on-board data acquisition system, another objective for this project was to investigate the capability of simulation tools to predict thermal environments of the probe/test article and its interior. This paper focuses on finite-element thermal analyses of the SPRITE probe during the arcjet tests. Several iterations were performed during the early design phase to provide critical design parameters and guidelines for testing. The thermal effects of ablation and pyrolysis were incorporated into the final higher-fidelity modeling approach by coupling the finite-element analyses with a two-dimensional thermal protection materials response code. Model predictions show good agreement with thermocouple data obtained during the arcjet test.

Agrawal, Parul↗

NASA NTRSDate not supplied

3D Material Response of the MSL Heatshield Using NuSil-Coated PICA

The Mars Science Laboratory (MSL) Entry, Descent and Landing Instrumentation (MEDLI) collected in-flight data largely used by the ablation community to verify and validate physics-based models for the response of the Phenolic Impregnated Carbon Ablator (PICA) material [1-4]. MEDLI data were recently used to guide the development of NASA’s high-fidelity material response models for PICA implemented in the Porous material Analysis Toolbox based on OpenFOAM (PATO) software [5-6]. A follow-up instrumentation suite, MEDLI2, was used for the Mars 2020 mission [7] after the large scientific impact of MEDLI. Recent analyses performed as part of MEDLI2 development drew the attention to significant effects of a protective coating to the aerothermal response of PICA. NuSil, a silicone-based overcoat sprayed onto the MSL heatshield, including the MEDLI plugs, as contamination control, is currently neglected in PICA ablation models. To mitigate the spread of phenolic dust from PICA, NuSil was applied to the entire MSL and Mars 2020 heatshields, including the MEDLI and MEDLI2 plugs. Ground testing of PICA-NuSil (PICA-N) models exhibited surface temperature jumps due to oxide scale formation and subsequent NuSil burn- off. It is therefore critical to include a model for the aerothermal response of the coating in ongoing code development and validation efforts. Figure 1 illustrates the PICA-N model implemented in PATO with a test case that shows a temperature jump and a change of recession rate at the wall after 20 seconds of simulation when the NuSil coating was fully removed.

Aerospace↗

NASA NTRS2010

Computational Analysis of Arc-Jet Wedge Tests Including Ablation and Shape Change

Coupled fluid-material response analyses of arc-jet wedge ablation tests conducted in a NASA Ames arc-jet facility are considered. These tests were conducted using blunt wedge models placed in a free jet downstream of the 6-inch diameter conical nozzle in the Ames 60-MW Interaction Heating Facility. The fluid analysis includes computational Navier-Stokes simulations of the nonequilibrium flowfield in the facility nozzle and test box as well as the flowfield over the models. The material response analysis includes simulation of two-dimensional surface ablation and internal heat conduction, thermal decomposition, and pyrolysis gas flow. For ablating test articles undergoing shape change, the material response and fluid analyses are coupled in order to calculate the time dependent surface heating and pressure distributions that result from shape change. The ablating material used in these arc-jet tests was Phenolic Impregnated Carbon Ablator. Effects of the test article shape change on fluid and material response simulations are demonstrated, and computational predictions of surface recession, shape change, and in-depth temperatures are compared with the experimental measurements.

Goekcen, Tahir↗

NASA NTRS2012

Numerical Simulation of Rocket Exhaust Interaction with Lunar Soil

This technology development originated from the need to assess the debris threat resulting from soil material erosion induced by landing spacecraft rocket plume impingement on extraterrestrial planetary surfaces. The impact of soil debris was observed to be highly detrimental during NASA s Apollo lunar missions and will pose a threat for any future landings on the Moon, Mars, and other exploration targets. The innovation developed under this program provides a simulation tool that combines modeling of the diverse disciplines of rocket plume impingement gas dynamics, granular soil material liberation, and soil debris particle kinetics into one unified simulation system. The Unified Flow Solver (UFS) developed by CFDRC enabled the efficient, seamless simulation of mixed continuum and rarefied rocket plume flow utilizing a novel direct numerical simulation technique of the Boltzmann gas dynamics equation. The characteristics of the soil granular material response and modeling of the erosion and liberation processes were enabled through novel first principle-based granular mechanics models developed by the University of Florida specifically for the highly irregularly shaped and cohesive lunar regolith material. These tools were integrated into a unique simulation system that accounts for all relevant physics aspects: (1) Modeling of spacecraft rocket plume impingement flow under lunar vacuum environment resulting in a mixed continuum and rarefied flow; (2) Modeling of lunar soil characteristics to capture soil-specific effects of particle size and shape composition, soil layer cohesion and granular flow physics; and (3) Accurate tracking of soil-borne debris particles beginning with aerodynamically driven motion inside the plume to purely ballistic motion in lunar far field conditions. In the earlier project phase of this innovation, the capabilities of the UFS for mixed continuum and rarefied flow situations were validated and demonstrated for lunar lander rocket plume flow impingement under lunar vacuum conditions. Applications and improvements to the granular flow simulation tools contributed by the University of Florida were tested against Earth environment experimental results. Requirements for developing, validating, and demonstrating this solution environment were clearly identified, and an effective second phase execution plan was devised. In this phase, the physics models were refined and fully integrated into a production-oriented simulation tool set. Three-dimensional simulations of Apollo Lunar Excursion Module (LEM) and Altair landers (including full-scale lander geometry) established the practical applicability of the UFS simulation approach and its advanced performance level for large-scale realistic problems.

Liever, Peter↗

NASA NTRS2012

Motion Imagery and Robotics Application (MIRA): Standards-Based Robotics

Martinez, Lindolfo↗

DOE OSTI2022

Uncertainty Quantification Framework for Predicting Material Response with Large Number of Parameters: Application to Creep Prediction in Ferritic-Martensitic Steels Using Combined Crystal Plasticity and Grain Boundary Models

This paper presents an uncertainty quantification (UQ) framework for the physics-based model prediction of material response with a large number of parameters. The application problem presented in this work is that of predicting creep in Grade 91 steel at 600°C. The material response is defined with a physically based microstructural model with constitutive equations emulating several observed phenomena in Grade 91 and embodied into an explicit geometry mesoscale finite element model for prior austenite grains and grain boundaries. Creep within the grains and in grain boundaries are represented by crystal plasticity for dislocation motion and a physics-based model for cavity growth and nucleation, respectively. The creep behavior of this material is influenced by several parameters, some of which have a wide range of variation based on experimental data. UQ combined with microstructural modeling can discover the core microstructural causes of experimental variability, leading to improved materials with lower variability in critical long-term material properties. In this study, we investigate the model's uncertainty to identify material properties that may be modified during production to increase creep life and analyze different components of the crystal plasticity model for improvements. For this purpose, a quantity of interest is defined as time to minimum creep rate, which correlates well to the creep failure of the material. A deep neural network model was trained and validated to be used as a surrogate for the finite element model. Then, a variance-based sensitivity analysis is performed on the surrogate model to find the Sobol indices of the input parameters in respect to the output quantity of interest. The Sobol indices are used to reduce the dimensionality of the model. Generalized polynomial chaos expansion is used on the reduced basis models to propagate the uncertainty from the input parameters to the quantity of interest using the deep neural network surrogate model. These results are benchmarked against uncertainty propagation using Monte Carlo simulations. In conclusion, the UQ performed through the reduced basis model captures almost all the uncertainty in the model with significantly fewer simulations, making it possible to perform the UQ directly via simulations with the finite element model rather than surrogate machine-learned models.

36 MATERIALS SCIENCE↗

NASA NTRS2013

Atmospheric Entry Studies for Venus Missions: 45 Sphere-Cone Rigid Aeroshells and Ballistic Entries

The present study considers direct ballistic entries into the atmosphere of Venus using a 45deg sphere-cone rigid aeroshell, a legacy shape that has been used successfully in the past in the Pioneer Venus Multiprobe Mission. For a number of entry mass and heatshield diameter combinations (i.e., various ballistic coefficients) and entry velocities, the trajectory space in terms of entry flight path angles between skip out and -30deg is explored with a 3DoF trajectory code, TRAJ. From these trajectories, the viable entry flight path angle space is determined through the use of mechanical and thermal performance limits on the thermal protection material and science payload; the thermal protection material of choice is entry-grade carbon phenolic, for which a material thermal response model is available. For mechanical performance, a 200 g limit is placed on the peak deceleration load experienced by the science instruments, and 10 bar is assumed as the pressure limit for entry-grade carbon-phenolic material. For thermal performance, inflection points in the total heat load distribution are used as cut off criteria. Analysis of the results shows the existence of a range of critical ballistic coefficients beyond which the steepest possible entries are determined by the pressure limit of the material rather than the deceleration load limit.

Prabhu, Dinesh K.↗

DOE OSTI2023

Improving dynamic collision frequencies: Impacts on dynamic structure factors and stopping powers in warm dense matter

Simulations and diagnostics of high-energy-density plasmas and warm dense matter rely on models of material response properties, both static and dynamic (frequency-dependent). Here, in this work, we systematically investigate variations in dynamic electron–ion collision frequencies ν(ω) in warm dense matter using data from a self-consistent-field average-atom model. We show that including the full quantum density of states, strong collisions, and inelastic collisions lead to significant changes in ν(ω). These changes result in red shifts and broadening of the plasmon peak in the dynamic structure factor, an effect observable in x-ray Thomson scattering spectra, and modify stopping powers around the Bragg peak. These changes improve the agreement of computationally efficient average-atom models with first-principles time-dependent density functional theory in warm dense aluminum, carbon, and deuterium.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRSDate not supplied

Analysis of MSL/MEDLI Entry Data with Coupled CFD and Material Response

The Mars Science Laboratory (MSL) was protected during its atmospheric entry by an instrumented heatshield using NASA's Phenolic Impregnated Carbon Ablator (PICA) material [1]. PICA is a lightweight carbon fiber/polymeric resin material that offers outstanding performances for protecting probes during planetary entry. The Mars Entry Descent and Landing Instrument (MEDLI) suite on MSL offers unique in-flight validation data for models of material response and atmospheric entry. MEDLI recorded, among other things, time-resolved in-depth temperature data of PICA using thermocouple sensors assembled in the MEDLI Integrated Sensor Plugs (MISP) [2]. The objective of this work is to showcase and analyze the coupling between the material response and the aerothermal environment. As shown in Figure 1, the workflow is divided into the following steps. First, the aerothermal properties are computed in the Data Parallel Line Relaxation (DPLR) code [3] and used with the Nonequilibrium air radiation (NEQAIR) program [8] to compute radiative heating. Second, the thermal response inside the material is computed in the Porous material Analysis Toolbox based on OpenFOAM (PATO) [4,5,6] using a fixed blowing correction parameter. Third, the pyrolysis gases computed in PATO are used as inputs to a blowing boundary condition within DPLR. Fourth, the new environment properties from DPLR are used in NEQAIR to provide an updated solution, then both the updated aerothermal environment and radiative heating are used in PATO without blowing correction. The third and fourth steps are then repeated until convergence in surface temperature is obtained. Convergence in the radiative heating is generally achieved before surface temperature, at which point the radiative heating is no longer updated. Char mass loss rates are forced to zero to produce a non-receding surface condition. For early time points in the trajectory, where flow around the MSL aeroshell is rarefied, the Direct Simulation Monte Carlo (DSMC) code, SPARTA [7], is used to compute the aerothermal environment. Iteration between PATO and SPARTA is not performed due to the computational cost of DSMC simulations. Preliminary results of the coupling between PATO and DPLR for the MSL heatshield atmospheric entry model are presented in Figures 2-4 at 65 seconds after entry interface. Figure 2 shows the surface temperature results from an uncoupled simulation in PATO with the blowing correction parameter applied (left) along with the coupled surface temperature after iteration (right). Figure 3 shows the surface temperature along the centerline from windward to leeward for easier comparison. Figure 4 shows the coupled and uncoupled pyrolysis gas blowing rate. Mars 2020 used a similar heatshield consisting of PICA for thermal protection during entry, descent, and landing. In preparation for Mars 2020 post-flight analysis, the predictive material response capability is benchmarked against flight data from MEDLI. This work represents an important milestone toward the development of validated predictive capabilities for designing thermal protection systems for planetary probes.

Thermal Protection Systems↗