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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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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Development of a Low-Cost, Subscale Test System to Evaluate Particle Impingement Erosion in Nozzle Ablative Materials

This viewgraph presentation gives an overview on the development of a low-cost, subscale test system to evaluate particle impingement erosion in nozzle ablative materials. Details are given on the need for a new test bed, solid fuel torch components, solid fuel torch test, additional uses for the solid fuel torch, the development of a supersonic blast tube (SSBT), and particle impingement material discrimination.

Lansing, Matthew D.↗
NASA NTRS2003

Finite-Rate Ablation Boundary Conditions for Carbon-Phenolic Heat-Shield

A formulation of finite-rate ablation surface boundary conditions, including oxidation, nitridation, and sublimation of carbonaceous material with pyrolysis gas injection, has been developed based on surface species mass conservation. These surface boundary conditions are discretized and integrated with a Navier-Stokes solver. This numerical procedure can predict aerothermal heating, chemical species concentration, and carbonaceous material ablation rate over the heatshield surface of re-entry space vehicles. In this study, the gas-gas and gas-surface interactions are established for air flow over a carbon-phenolic heatshield. Two finite-rate gas-surface interaction models are considered in the present study. The first model is based on the work of Park, and the second model includes the kinetics suggested by Zhluktov and Abe. Nineteen gas phase chemical reactions and four gas-surface interactions are considered in the present model. There is a total of fourteen gas phase chemical species, including five species for air and nine species for ablation products. Three test cases are studied in this paper. The first case is a graphite test model in the arc-jet stream; the second is a light weight Phenolic Impregnated Carbon Ablator at the Stardust re-entry peak heating conditions, and the third is a fully dense carbon-phenolic heatshield at the peak heating point of a proposed Mars Sample Return Earth Entry Vehicle. Predictions based on both finite-rate gas- surface interaction models are compared with those obtained using B' tables, which were created based on the chemical equilibrium assumption. Stagnation point convective heat fluxes predicted using Park's finite-rate model are far below those obtained from chemical equilibrium B' tables and Zhluktov's model. Recession predictions from Zhluktov's model are generally lower than those obtained from Park's model and chemical equilibrium B' tables. The effect of species mass diffusion on predicted ablation rate is also examined.

Chen, Y.-K.↗
NASA NTRS2012

Arcjet Testing and Thermal Model Development for Multilayer Felt Reusable Surface Insulation

Felt Reusable Surface Insulation was used extensively on leeward external surfaces of the Shuttle Orbiter, where the material is reusable for temperatures up to 670 K. For application on leeward surfaces of the Orion Multi-Purpose Crew Vehicle, where predicted temperatures reach 1620 K, the material functions as a pyrolyzing conformal ablator. An arcjet test series was conducted to assess the performance of multilayer Felt Reusable Surface Insulation at high temperatures, and a thermal-response, pyrolysis, and ablation model was developed. Model predictions compare favorably with the arcjet test data

Milos, Frank S.↗
NASA NTRS2016

Launch Pad in a Box

NASA Kennedy Space Center (KSC) is developing a new deployable launch system capability to support a small class of launch vehicles for NASA and commercial space companies to test and launch their vehicles. The deployable launch pad concept was first demonstrated on a smaller scale at KSC in 2012 in support of NASA Johnson Space Center's Morpheus Lander Project. The main objective of the Morpheus Project was to test a prototype planetary lander as a vertical takeoff and landing test-bed for advanced spacecraft technologies using a hazard field that KSC had constructed at the Shuttle Landing Facility (SLF). A steel pad for launch or landing was constructed using a modular design that allowed it to be reconfigurable and expandable. A steel flame trench was designed as an optional module that could be easily inserted in place of any modular steel plate component. The concept of a transportable modular launch and landing pad may also be applicable to planetary surfaces where the effects of rocket exhaust plume on surface regolith is problematic for hardware on the surface that may either be damaged by direct impact of high speed dust particles, or impaired by the accumulation of dust (e.g., solar array panels and thermal radiators). During the Morpheus free flight campaign in 2013-14, KSC performed two studies related to rocket plume effects. One study compared four different thermal ablatives that were applied to the interior of a steel flame trench that KSC had designed and built. The second study monitored the erosion of a concrete landing pad following each landing of the Morpheus vehicle on the same pad located in the hazard field. All surfaces of a portable flame trench that could be directly exposed to hot gas during launch of the Morpheus vehicle were coated with four types of ablatives. All ablative products had been tested by NASA KSC and/or the manufacturer. The ablative thicknesses were measured periodically following the twelve Morpheus free flight tests. The thermal energy from the Morpheus rocket exhaust plume was only found to be sufficient to cause appreciable ablation of one of the four ablatives that were tested. The rocket exhaust plume did cause spalling of concrete during each descent and landing on a landing pad in the hazard field. The Extended Abstract ASE Earth and Space Conference April, 2016 - Orlando, FL concrete surface was laser scanned following each Morpheus landing, and the total volume of spalled concrete that eroded between the first and final landings of the Morpheus Project's test campaign was estimated. This paper will also describe a new deployable launch system (DLS) capability that is being developed at KSC and was publicly announced in May 2015 (KSC Partnerships, 2015). The DLS is a set of multi-user Ground Support Equipment that will be used to test and launch small class launch vehicles. The system is comprised of four main elements: the Launch Stand, the Flame Deflector, the Pad Apron and the KAMAG transporter. The system elements are designed to be deployed at launch or test sites within the KSC/CCAFS boundaries. The DLS is intended to be used together with the Fluid and Electrical System of the Universal Propellant Servicing Systems and Mobile Power Data and Communications Unit.

Ablatives Testing↗
NASA NTRS2016

Launch Pad in a Box

NASA Kennedy Space Center (KSC) is developing a new deployable launch system capability to support a small class of launch vehicles for NASA and commercial space companies to test and launch their vehicles. The deployable launch pad concept was first demonstrated on a smaller scale at KSC in 2012 in support of NASA Johnson Space Center's Morpheus Lander Project. The main objective of the Morpheus Project was to test a prototype planetary lander as a vertical takeoff and landing test-bed for advanced spacecraft technologies using a hazard field that KSC had constructed at the Shuttle Landing Facility (SLF). A steel pad for launch or landing was constructed using a modular design that allowed it to be reconfigurable and expandable. A steel flame trench was designed as an optional module that could be easily inserted in place of any modular steel plate component. The concept of a transportable modular launch and landing pad may also be applicable to planetary surfaces where the effects of rocket exhaust plume on surface regolith is problematic for hardware on the surface that may either be damaged by direct impact of high speed dust particles, or impaired by the accumulation of dust (e.g., solar array panels and thermal radiators). During the Morpheus free flight campaign in 2013-14, KSC performed two studies related to rocket plume effects. One study compared four different thermal ablatives that were applied to the interior of a steel flame trench that KSC had designed and built. The second study monitored the erosion of a concrete landing pad following each landing of the Morpheus vehicle on the same pad located in the hazard field. All surfaces of a portable flame trench that could be directly exposed to hot gas during launch of the Morpheus vehicle were coated with four types of ablatives. All ablative products had been tested by NASA KSC and/or the manufacturer. The ablative thicknesses were measured periodically following the twelve Morpheus free flight tests. The thermal energy from the Morpheus rocket exhaust plume was only found to be sufficient to cause appreciable ablation of one of the four ablatives that were tested. The rocket exhaust plume did cause spalling of concrete during each descent and landing on a landing pad in the hazard field. The Extended Abstract ASE Earth and Space Conference April, 2016 - Orlando, FL concrete surface was laser scanned following each Morpheus landing, and the total volume of spalled concrete that eroded between the first and final landings of the Morpheus Project's test campaign was estimated. This paper will also describe a new deployable launch system (DLS) capability that is being developed at KSC and was publicly announced in May 2015 (KSC Partnerships, 2015). The DLS is a set of multi-user Ground Support Equipment that will be used to test and launch small class launch vehicles. The system is comprised of four main elements: the Launch Stand, the Flame Deflector, the Pad Apron and the KAMAG transporter. The system elements are designed to be deployed at launch or test sites within the KSC/CCAFS boundaries. The DLS is intended to be used together with the Fluid and Electrical System of the Universal Propellant Servicing Systems and Mobile Power Data and Communications Unit

Mobile Launch Pad Development↗
DOE OSTI2026

Lithography-Free Mesa Isolation by Laser Ablation for Multijunction III-V Photovoltaic Space Power Generation

Eliminating photolithography from photovoltaic device processing is a significant opportunity for cost reduction and increased manufacturing throughput. In this work, we test femtosecond laser ablation and scribing as an alternative to contact photolithography and wet chemical etching for mesa isolation of multijunction devices. We demonstrate that upright multijunction devices isolated by using the laser as a scribe to cleave through the substrate had virtually no performance loss when compared to a baseline device processed with photolithography. By contrast, devices isolated by laser ablating through the active layers have performance losses that cannot be fully eliminated with postprocess etching. This demonstration of photolithography-free mesa isolation with no performance losses is promising as a pathway to less expensive and higher throughput III-V device manufacturing.

14 SOLAR ENERGY↗
DOE OSTI2025

Laser Ablation for Low-Cost Multijunction III-V Solar Cell Mesa Isolations

Eliminating photolithography from solar cell processing is a significant opportunity for cost reduction for III-V solar cells. In this work, we test femtosecond laser ablation and scribing as an alternative to contact photolithography and wet chemical etching for mesa isolation, when processing multijunction cells. We demonstrate that upright multijunction solar cells isolated by using the laser as a scribe to cleave through the substrate had virtually no performance loss when compared to a baseline cell processed with photolithography. By contrast, cells isolated by laser ablating through the active layers have performance losses that cannot be fully eliminated with post-processing etches. This demonstration of photolithography-free mesa isolation with no performance losses is promising for less expensive III-V manufacturing.

14 SOLAR ENERGY↗
NASA NTRS2011

A Boundary Condition Relaxation Algorithm for Strongly Coupled, Ablating Flows Including Shape Change

Implementations of a model for equilibrium, steady-state ablation boundary conditions are tested for the purpose of providing strong coupling with a hypersonic flow solver. The objective is to remove correction factors or film cooling approximations that are usually applied in coupled implementations of the flow solver and the ablation response. Three test cases are considered - the IRV-2, the Galileo probe, and a notional slender, blunted cone launched at 10 km/s from the Earth's surface. A successive substitution is employed and the order of succession is varied as a function of surface temperature to obtain converged solutions. The implementation is tested on a specified trajectory for the IRV-2 to compute shape change under the approximation of steady-state ablation. Issues associated with stability of the shape change algorithm caused by explicit time step limits are also discussed.

Gnoffo, Peter A.↗
NASA NTRS1973

Investigation of low-cost fabrication of ablative heat shields

The fabrication, testing, and evaluation of materials and techniques employed in the fabrication of ablative heat shield panels are described. Results of this effort show projected reductions in labor man-hours for dielectric curing of panels when compared to panels molded in a steam-heated press. In addition, panels were fabricated with more than one density within the cross-section. These dual-density panels show significant weight and cost reduction potentials.

Massions, V. P.↗
NASA NTRSDate not supplied

Towards Thermal Protection System Certification by Analysis: Identification and Implication of Features

The thermal protection systems (TPS) to be used for upcoming sample return missions (e.g., Mars Sample Return) and future crewed missions to the Moon and Mars are subject to stringent reliability criteria. The certification of TPS is conducted through extensive testing, which can include Arc Jet testing to understand ablative behavior and non-destructive evaluation (NDE) to identify features that could lead to sub-optimal performance during entry. Unexpected features observed during fabrication of large-scale articles often require additional testing to certify, which in the very worst cases can impact schedule and contribute to cost.

J. B. Haskins↗
NASA NTRS2014

Remote Recession Sensing of Ablative Heat Shield Materials

Tests were performed to demonstrate the feasibility of a new method of measuring surface recession of a material sample during arc-jet testing in the NASA Ames mARC subscale developmental facility. The measurement principle was inspired through tracer elements such as Ca and Na which were seen in the spectra taken during the airborne observation campaign of the Stardust re-entry and which could be clearly observed standing out against the emission spectra emitted by postshock layer and glowing surface of the re-entry capsule. The measurement principle involves seeding of the heat shield materials at a defined depth with tracer elements which show strong and characteristic emission lines in the post shock plasma. Once the material recession reaches the seeding depth, these elements get into the hot plasma and show up in the emission spectra. The methodology was successfully demonstrated during arc-jet testing of phenolic impregnated carbonablator (PICA) material which was seeded in depth with a mixture of NaCl and MgCl in powder form. In the emission spectroscopy data, the emission lines of Mg and Na showed up about 1.5 seconds after probe insertion into the arc-jet plasma and vanished after another 2.5 seconds when recessionhad consumed the seeding material. From these data, a recession rate of about 1 mm/s is estimated.The heat flux during the test was measured to be 2575 W/sq cm on a hemispherical heat flux probewhich corresponds to a heat flux of 1036 W/sq cm on the rectangular test articles. An estimate for a lower limit of the surface temperature of 2800K during the test was obtained by fitting Planck radiation to the continuum spectra emitted by the PICA sample. Typical recession rates of PICA during testing in the large arc-jet facilities at similar test conditions are reported to be on the order of 0.05 to 0.1 cm/s which agrees well with the recession rates of 0.05-0.06 cm/s estimated from the emission spectroscopy data. Further tests under better controlled conditions are suggested to quantify this measurement method. Through a different choice of seeding materials with lower melting point, an extension of the measurement principle to monitor char depth seems feasible but was not yet demonstrated. Possible applications besides ground testing are recession and possibly char depth measurements during real re-entry. Detection through emission spectroscopy could be accomplished through ground based or airborne observation as performed during the Stardust and Hayabusa re-entries, or through on-board spectrometers. A suitable mission would be the re-entryof the OSIRIS-REX mission planned for late 2023. The measured data are presented and interpreted, the results and details of future applications are discussed.

instrumentation↗
NASA NTRS1981

Shuttle solid rocket motor nozzle alternate ablative evaluation

A series of subscale tests are shown to suggest that a lower-cost ablative material than the rayon-based carbon ablative currently used in the Space Shuttle Solid Rocket Motor (SRM) may be used as a substitute. Six such ablatives with outstanding performance characteristics, using spun PAN and continuous pitch and PAN fibers instead of the present, continuous rayon, were identified in the course of tests with HTPB/AL/AP solid propellant grains with a burn time of 12 sec. The test nozzle features an initial throat diameter of 2.2 in. and a 6.1 expansion ratio. In addition to nozzle structural feature drawings, extensive test data tables and propellant formulation and properties tables are provided.

Powers, L. B.↗
NASA NTRSDate not supplied

Artemis I Space Launch System Base Heat Shield Thermal Protection System Performance

The Space Launch System (SLS) Core Stage base heat shield experienced the highest external heating environments on the entire launch vehicle during Artemis I ascent flight. This result was consistent with design predictions. The base heat shield experiences P50 cork combustion dynamics at low altitudes, plume-induced recirculation at moderate altitudes and then in-space base flow physics out to Main Engine Cut-Off (MECO). The base heat shield thermal protection system (TPS) is composed of a P50 cork ablator which is bonded to a substrate. The heat shield protects the gimbal actuation system, RS-25 turbomachinery systems and other aft section sensitive components during ascent. This paper estimates the base heat shield TPS performance from Artemis I using flight data from the NASA Langley Research Center’s Scientifically Calibrated In-Flight Imagery (SCIFLI) Airborne Multispectral Imager (SAMI), development flight instrumentation (DFI) and other TPS recession flight measurements. Predictions from computational and ground test-derived engineering ablation models and observations are also applied. Since no base heat shield substrate thermocouple data were obtained for Artemis I, an estimate of the TPS performance data is derived here. This data assesses thermal margin of the SLS Core Stage base heat shield and best informs the Artemis II Crewed mission to the moon.

aerothermodynamics↗
NASA NTRS2011

Comparison of Ablation Predictions for Carbonaceous Materials Using CEA and JANAF-Based Species Thermodynamics

In most previous work at NASA Ames Research Center, ablation predictions for carbonaceous materials were obtained using a species thermodynamics database developed by Aerotherm Corporation. This database is derived mostly from the JANAF thermochemical tables. However, the CEA thermodynamics database, also used by NASA, is considered more up to date. In this work, the FIAT code was modified to use CEA-based curve fits for species thermodynamics, then analyses using both the JANAF and CEA thermodynamics were performed for carbon and carbon phenolic materials over a range of test conditions. The ablation predictions are comparable at lower heat fluxes where the dominant mechanism is carbon oxidation. However, the predictions begin to diverge in the sublimation regime, with the CEA model predicting lower recession. The disagreement is more significant for carbon phenolic than for carbon, and this difference is attributed to hydrocarbon species that may contribute to the ablation rate.

Milos, Frank S.↗