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NASA NTRS2019

Challenges and Opportunities For Ensuring Entry System Technology Readiness For Ice Giants Probe Missions

The Ice Giants represent a distinct class of planets within our solar system, and appear to be similar to most exoplanets that have been detected thus far. Exploring Ice Giants in our Solar System would allow us to better understand their formation and evolution processes, and thus help establish scientific links to exoplanets. In situ exploration using probes similar to Galileo, along with an orbiter or a relay spacecraft, will require entry followed by deployment of the descent probe containing science instruments into Uranus or Neptune atmosphere. The challenge is not in the deployment of the probe, but in the atmospheric entry prior to deployment. The entry system has to have a capable, robust and efficient ablative thermal protection system (TPS) designed to protect the descent probe from the thermal and mechanical entry loads. Although entries into Ice Giants may not be as demanding as the Galileo entry at Jupiter, the entry environments will be more severe than environments for Mars, Sample Return missions, and Venus, and will therefore require robust TPS. While Galileo Probe’s success, nearly 25 years ago, should give us confidence, the recession data from the Galileo entry informs us that the entry environment was under predicted and the design thickness was barely adequate. The lesson learned from Galileo probe for future Ice Giant missions will require us to be cautious and demand a more robust design. The TPS technology used on Galileo entry system no longer exists due to atrophy of manufacturing processes. Instead of attempting to revive Galileo-legacy TPS technology, NASA invested in a new and innovative TPS called HEEET (Heat-shield for Extreme Entry Environment Technology). HEEET has been matured, and is now ready to support future missions not only to the Ice Giants but also for Venus, high-speed sample return, and Saturn probe missions. This lead talk, intended for the technology section of the workshop, will cover entry, descent, and deployment (EDD), with an emphasis on entry. A brief history of the TPS challenges for extreme entry missions will be given along with a quick overview of the concept of operations for EDD. The development and maturation of HEEET system capability will be described. Data gathered in ground-test facilities in the US will be highlighted to show that the technology is mature and ready for Ice Giant missions. All thermal protection systems carry some risk as a result of ground test limitations and Ice Giant missions present some unique challenges. These challenges are not only technical, but also due to limitations in the currently established manufacturing and integration. In addition, the concerns that arise due to potential for atrophy for future Ice Giant mission a decade or more from now will be analyzed. Plausible avenues for mitigation will be presented. There are two companion planned presentations by Dr. Prabhu and Dr. Hwang will dive deeper in the challenges and opportunities. This intended talk will set the stage for their presentations.

Venkatapathy, Ethiraj↗
NASA NTRS2019

Challenges and Opportunities for Ensuring Entry System Technology Readiness for Ice Giants Probe Missions

The Ice Giants represent a distinct class of planets within our solar system, and appear to be similar to most exoplanets that have been detected thus far. Exploring Ice Giants in our Solar System would allow us to better understand their formation and evolution processes, and thus help establish scientific links to exoplanets. In situ exploration using probes similar to Galileo, along with an orbiter or a relay spacecraft, will require entry followed by deployment of the descent probe containing science instruments into Uranus or Neptune atmosphere. The challenge is not in the deployment of the probe, but in the atmospheric entry prior to deployment. The entry system has to have a capable, robust and efficient ablative thermal protection system (TPS) designed to protect the descent probe from the thermal and mechanical entry loads. Although entries into Ice Giants may not be as demanding as the Galileo entry at Jupiter, the entry environments will be more severe than environments for Mars, Sample Return missions, and Venus, and will therefore require robust TPS. While Galileo Probe’s success, nearly 25 years ago, should give us confidence, the recession data from the Galileo entry informs us that the entry environment was under-predicted and the design thickness was barely adequate. The lesson learned from the Galileo probe for future Ice Giant missions will require us to be cautious and demand a more robust design. The TPS technology used on the Galileo entry system no longer exists due to atrophy of manufacturing processes. Instead of attempting to revive Galileo-legacy TPS technology, NASA invested in a new and innovative TPS called HEEET (Heat-shield for Extreme Entry Environment Technology). HEEET has been matured, and is now ready to support future missions not only to the Ice Giants but also for Venus, high-speed sample return, and Saturn probe missions. This lead talk, intended for the technology section of the workshop, will cover entry, descent, and deployment (EDD), with an emphasis on entry. A brief history of the TPS challenges for extreme entry missions will be given, along with a quick overview of the concept of operations for EDD. The development and maturation of HEEET system capability will be described. Data gathered in ground-test facilities in the US will be highlighted to show that the technology is mature and ready for Ice Giant missions. All thermal protection systems carry some risk as a result of ground test limitations and Ice Giant missions present some unique challenges. These challenges are not only technical, but also due to limitations in the currently established manufacturing and integration. In addition, the concerns that arise due to the potential for atrophy for future Ice Giant missions a decade or more from now will be analyzed. Plausible avenues for mitigation will be presented. There are two planned companion presentations by Dr. Prabhu and Dr. Hwang that will dive deeper into the challenges and opportunities. This intended talk will set the stage for their presentations.

Venkatapathy, Ethiraj↗
NASA NTRS2019

TUFROC Thermal Protection System

Toughened Unipiece Fibrous Reinforced Oxidation-resistant Composite (TUFROC) is a tiled Thermal Protection System (TPS) suitable for reusable entry heating at 2900+ °F and with single use potential up to at least 3600 °F. TUFROC was initially developed for NASA's X-37 project and ultimately resulted in use on the Air Force X-37B as the wing leading edge (WLE) of the vehicle. TUFROC has similar high temperature capability compared with carbon/carbon, but is manufactured at an order of magnitude lower cost & faster schedule.

thermal protection system↗
NASA NTRS2014

Thermal Testing of Planetary Probe TPS in Extreme Entry Environments

High temperature testing of thermal protection system (TPS) materials is a critical aspect of heat-shield materials development, as it determines the suitability and performance envelope of the materials. The present talk provides an overview of recent updates to NASAs IHF and AEDCs H3 high temperature arcjet test facilities that to enable higher heat flux (5000-8000 Wcm2) and high pressure (5-14 atm) testing of TPS. Some recent thermal tests of fully dense carbon phenolic will be discussed in this paper. These new facility upgrades will help improve the TRL level of novel TPS materials and will help qualifycertify heritage TPS material candidates for future missions that are expected to encounter extreme entry conditions, such as entry into Venus or Saturn.

Gasch, M.↗
NASA NTRS1998

X-33 Base Region Thermal Protection System Design Study

The X-33 is an advanced technology demonstrator for validating critical technologies and systems required for an operational Single-Stage-to-Orbit (SSTO) Reusuable Launch Vehicle (RLV). Currently under development by a unique contractor/government team led by Lockheed- Martin Skunk Works (LMSW), and managed by Marshall Space Flight Center (MSFC), the X-33 will be the prototype of the first new launch system developed by the United States since the advent of the space shuttle. This paper documents a design trade study of the X-33 base region thermal protection system (TPS). Two candidate designs were evaluated for thermal performance and weight. The first candidate was a fully reusable metallic TPS using Inconel honeycomb panels insulated with high temperature fibrous insulation, while the second was an ablator/insulator sprayed on the metallic skin of the vehicle. The TPS configurations and insulation thickness requirements were determined for the predicted main engine plume heating environments and base region entry aerothermal environments. In addition to thermal analysis of the design concepts, sensitivity studies were performed to investigate the effect of variations in key parameters of the base TPS analysis.

Lycans, Randal W.↗
NASA NTRS2017

MELDI2 Do No Harm Test Series

Mars 2020 will fly the Mars Entry, Descent, and Landing Instrumentation II (MEDLI2) sensor suite consisting of a total of seventeen instrumented thermal sensor plugs, eight pressure transducers, two heat flux sensors, and one radiometer embedded in the thermal protection system (TPS). Of the MEDLI2 instrumentation, eleven instrumented thermal plugs and seven pressure transducers will be installed on the heatshield of the Mars 2020 vehicle while the rest will be installed on the backshell. The goal of the MEDLI2 instrumentation is to directly inform the large performance uncertainties that contribute to the design and validation of a Mars entry system. A better understanding of the entry environment and TPS performance could lead to reduced design margins enabling a greater payload mass-fraction and smaller landing ellipses. To prove that the MEDLI2 system will not degrade the performance of the Mars 2020 TPS, an Aerothermal Do No Harm (DNH) test series was designed and conducted. Like Mars 2020's predecessor, Mars Science Laboratory (MSL), the heatshield material will be Phenolic Impregnated Carbon Ablator (PICA); the Mars 2020 entry conditions are enveloped by the MSL design environments, therefore the development and qualification testing performed during MEDLI is sufficient to show that the similar MEDLI2 heatshield instrumentation will not degrade PICA performance. However, given that MEDLI did not include any backshell instrumentation, the MEDLI2 team was required to design and execute a DNH test series utilizing the backshell TPS material (SLA-561V) with the intended flight sensor suite. To meet the requirements handed down from Mars 2020, the MEDLI2 DNH test series emphasized the interaction between the MEDLI2 sensors and sensing locations with the surrounding backshell TPS and substrucutre. These interactions were characterized by performing environmental testing of four 12" by 12" test panels, which mimicked the construction of the backshell TPS and the integration of the MEDLI2 sensors as seen in Figure 1. The testing included thermal vacuum/ cycling, random vibration, shock, and arc jet testing. The test panels were fabricated by Lockheed Martin, establishing techniques that will be utilized during the Mars 2020 vehicle installation. Each test panel included one thermal sensor plug (two embedded thermocouples), one heat flux sensor, and multiple pressure port holes for evaluation. This presentation will discuss the planning and execution of the MEDLI2 DNH test series. Selected highlights and results of each environmental test will be presented, and lessons learned will be addressed that will feed forward into the planning for the MEDLI2 flight system certification testing.

Heatshield↗
NASA NTRS2018

Overview of Recent EAST Testing, Modeling & Analysis

Shock Layer Radiation at NASA Ames - Background: Complex aerothermal and thermochemical phenomena of planetary entry define convective and radiative heating. A spacecraft's TPS (Thermal Protective System) mitigates heat transfer to substructure. Successful TPS design relies on verifiable characterization of these phenomena in the anticipated flight environment. - Approach: EAST (Electric Arc Shock Tube) [facility at Ames] simulates high-enthalpy, real-gas phenomena encountered by hypersonic vehicles entering planetary atmospheres by spectrally imaging the flow behind a moving shock wave. - Goal: Validate aerothermal models (DPLR (Data Parallel Line Relaxation Code) and NEQAIR (Nonequilibrium Radiative Transport and Spectra Program)), inform model improvements, reduce uncertainty and quantify design uncertainties. - Recent Relevant Projects: MSL (Mars Science Laboratory) & Mars 2020, InSight, OSIRIS-REx (Origins Spectral Interpretation Resource Identification Security Regolith Explorer), Orion EFT-1 (Exploration Flight-1) and EM-1 (Exploration Mission-1) and New Frontiers.

Brandis, Aaron↗
NASA NTRS2014

Fundamental Property Requirements for Thermal and Mechanical Response Analysis of Thermal Protection Materials and Systems

Spacecraft that are designed to reenter the Earth's atmosphere, or enter the atmosphere of another planet, require Thermal Protection Systems (TPS) in order to survive the extreme thermal environments during the atmospheric flight. Analytical modeling of thermal and mechanical response is a fundamental aspect of the design of TPS and development of TPS materials. The analyses are used to understand the response of the materials and systems under representative environments. Performing these analyses, and evaluating the results, requires a variety of fundamental inputs, including: thermal and mechanical material properties; predicted or measured ground test and flight environments; and information about adjacent structure or attachments. We explain the nature of the analyses, highlight the essential fundamental data that are required, and describe the impact of the accuracy in the input data on the final results. We also describe the important priorities in material characterization testing in support of analyses.

Squire, Thomas↗
NASA NTRSDate not supplied

Robust and Mass Efficient Thermal Protection Systems for Future Venus Missions

Several international Venus missions, both orbiter, and in-situ probe are in the works after a prolonged absence. Future missions are expected to be long-duration lander missions and balloon missions to investigate the cloud layer. The entry mass for these in-situ missions will be significantly higher, and the aeroshell will be larger, than previous missions. Two cardinal requirements govern the selection and use of thermal protection systems (TPS), namely, robustness to assure mission safety during entry and mass efficiency so that the useful mass for science is maximized. One cannot trade mission safety for mass when it comes to TPS. The robustness of the TPS is a paramount requirement as it is a single point of system failure. At the same time, TPS mass is carried for the entire mission duration prior to entry, and any excess TPS mass is at the cost of science payload. Future missions will benefit enormously from TPS options with mass and performance benefits far beyond advanced carbon-carbon (ACC) that is currently proposed for the DAVINCI mission. NASA STMD, and SMD jointly invested in the development of 3-D woven thermal protection systems in the last decade, and as a result, the Heat-shield for Extreme Entry Environment Technology (HEEET) TPS has been matured to TRL 6. It is ready for future mission use including Venus. The HEEET project focused on developing a broad technology base, applicable for missions not only to Venus, but also to Saturn, the Ice Giants, and higher speed sample return missions such as Mars Sample Return requiring extreme robustness due to bio-hazards. The dual-layer HEEET (DL-HEEET) is proven to be extremely robust. DL-HEEET performed well in arc jet and laser testing conditions where heritage carbon-phenolic failed. HEEET also proved to be more mass efficient compared to Carbon-Phenolic. Recently, the principal author was invited to present his perspectives to the 2023-2032 Planetary Sciences Decadal Venus subcommittee on the current state of TPS for future Venus missions [1]. In addition to pointing out successful TPS and other developments in the last decade in support of entry systems, the principal author made two findings: 1) importance of and need to sustain TPS capabilities that took nearly a decade to develop and 2) the opportunity to further optimize TPS mass without sacrificing robustness to further enable future in-situ missions. This talk will focus on the above two recommendations and provide the rationale for them. The intent of the talk is to seek advocacy from the VEXAG community for the criticality of TPS sustainment and the benefits of 3D woven TPS optimization. TPS Capability Sustainment: HEEET development was necessitated by the atrophy of heritage carbon-phenolic. Atrophy has impacted other TPS materials as well. Avcoat, the TPS that successfully allowed astronauts to explore the Moon in the 1960s and 70s, took nearly a decade and $10’sM to recover in support of Orion/Artemis. One of the most used TPS materials, SLA 561V, had to be recovered prior to its use on Mars Pathfinder. Phenolic Impregnated Carbon Ablator (PICA), the TPS that replaced SLA 561V on MSL, has undergone multiple replacements and recovery due to constituent rayon changes. Recently, NASA invested in a domestic rayon replacement program and also invested in FMI to consolidate PICA capability for NASA missions, as a result of FMI’s decision to discontinue commercial FiberForm, which is needed for PICA. TPS used for planetary missions are unique and have no other commercial or defense use. In addition, low mission cadence is also a driver for TPS atrophy. Hence, NASA, as the steward, must take steps to ensure and sustain TPS capabilities. In this talk, we outline steps NASA can take to keep abreast of emerging risks and target risk mitigation steps to ensure TPS capability sustainment for Venus and other extreme environment missions. Next Generation of Mass efficient and Robust TPS: NASA invested in an alternate TPS to PICA based on felt-technology called Conformal-PICA which has the potential to save 30% - 50% mass over PICA. The development was discontinued at a Technology Readiness Level (TRL) of ~ 5. 3D Mid-Density Carbon Phenolic (3MDCP) is a single layer variant of HEEET, based on the insulating layer only (SL-HEEET) and currently baselined for the Mars Sample Return Mission Earth Entry System due to its mass efficiency (30% more mass efficient than DL- HEEET). Currently, SL-HEEET is limited to aeroshell diameters of < 1.3m. The SL-HEEET was compared to DL-HEEET in the recent ADVENT flag-ship class mission study in support of the Planetary Science Decadal. SL HEEET was the recommended TPS based on 30% mass savings for both the balloon and lander missions. Given C-PICA and SL-HEEET have superior reliability and mass efficiency, advocacy from VEXAG is sought for completing their further development to TRL 5/6 in this decade so as to enable TPS readiness for future missions.

Thermal Protection Systems↗
NASA NTRSDate not supplied

Thermal Protection System P50 Cork Char Response Characterization to Ascent Flight Shear and Heating Environments

NASA’s Space Launch System (SLS) experienced deflagration of the acreage of the Core Stage base heat shield during the Green Run hot-fire test campaigns and Artemis I flight. The burning products from the base heat shield during Green Run hot-fire test operation led to concerns in aerothermal environments and thermal protection system (TPS) performance prior to Artemis I flight. Updated design thermal environments accounting for cork combustion were developed using Green Run measurements and assessed prior to Artemis I, resulting in increased TPS thickness for the base heat shield. This work documents a highly controlled ground test within the NASA Marshall Space Flight Center’s Propulsion Test Branch Hot Gas Facility (HGF) and investigates the P50 cork TPS response due to sensitivity changes in radiative heat rates and surface shear stress. Prior to testing at the HGF, most of the P50 cork panels had a thick layer of char due to the cork combustion process replicated in a thermal vacuum chamber. SLS ascent shear stress and heating rate profile were simulated within the HGF by running the combustion-driven wind tunnel at off-nominal conditions and Mach numbers below 1. This test data provided insight into aerothermal measurements from Artemis I flight as well as informing updated base heating design environments for Artemis II. An in-depth understanding of the TPS P50 cork char response and observations is presented for launch vehicle flight ascent environments.

aerothermodynamics↗
NASA NTRS2017

Parametric Study of an Ablative TPS and Hot Structure Heatshield for a Mars Entry Capsule Vehicle

The National Aeronautics and Space Administration is planning to send humans to Mars. As part of the Evolvable Mars Campaign, different en- try vehicle configurations are being designed and considered for delivering larger payloads than have been previously sent to the surface of Mars. Mass and packing volume are driving factors in the vehicle design, and the thermal protection for planetary entry is an area in which advances in technology can offer potential mass and volume savings. The feasibility and potential benefits of a carbon-carbon hot structure concept for a Mars entry vehicle is explored in this paper. The windward heat shield of a capsule design is assessed for the hot structure concept as well as an ablative thermal protection system (TPS) attached to a honeycomb sandwich structure. Independent thermal and structural analyses are performed to determine the minimum mass design. The analyses are repeated for a range of design parameters, which include the trajectory, vehicle size, and payload. Polynomial response functions are created from the analysis results to study the capsule mass with respect to the design parameters. Results from the polynomial response functions created from the thermal and structural analyses indicate that the mass of the capsule was higher for the hot structure concept as compared to the ablative TPS for the parameter space considered in this study.

Langston, Sarah L.↗
NASA NTRS1995

Development of processing techniques for advanced thermal protection materials

The main purpose of this work has been in the development and characterization of materials for high temperature applications. Thermal Protection Systems (TPS) are constantly being tested, and evaluated for increased thermal shock resistance, high temperature dimensional stability, and tolerance to environmental effects. Materials development was carried out through the use of many different instruments and methods, ranging from extensive elemental analysis to physical attributes testing. The six main focus areas include: (1) protective coatings for carbon/carbon composites; (2) TPS material characterization; (3) improved waterproofing for TPS; (4) modified ceramic insulation for bone implants; (5) improved durability ceramic insulation blankets; and (6) ultra-high temperature ceramics. This report describes the progress made in these research areas during this contract period.

Selvaduray, Guna S.↗
NASA NTRS1990

Remtech SSME nozzle design TPS

Thermal damage to the Space Shuttle Main Engine (SSME) aft manifold Thermal Protection System (TPS) has been observed for flights STS-8 through STS-13. This damaged area is located on the ME2 and ME3 and extends over a region of approximately one square foot. Total failure or burn-through of the TPS could lead to severe thermal damage of the SSME manifold and loss of an engine nozzle necessitating nozzle replacement causing significant schedule delays and cost increases. Thermal damage to the manifold can be defined as a situation where the manifold temperature becomes greater than 1300 F; thereby causing loss of heat treatment in the nozzle. Results of Orbiter/nozzle wind tunnel tests and Hot Gas Facility tests of the TPS are presented. Aerothermal and thermal analysis models for the SSME aft manifold are discussed along with the flight predictions, design trajectory and design environment. Finally, the TPS design concept and TPS thermal response are addressed.

Bancroft, Steven A.↗
NASA NTRS2003

Ceramic Foams for TPS Applications

Ceramic foams have potential in many areas of Thermal Protection Systems (TPS) including acreage and tile leading edges as well as being suitable as a repair approach for re-entry vehicles. NASA Ames is conducting ongoing research in developing lower-density foams from pre-ceramic polymer routes. One of the key factors to investigate, when developing new materials for re-entry applications, is their oxidation behavior in the appropriate re-entry environment which can be simulated using ground based arc jet (plasma jet) testing. Arc jet testing is required to provide the appropriate conditions (stagnation pressures, heat fluxes, enthalpies, heat loads and atmospheres) encountered during flight. This work looks at the response of ceramic foams (Si systems) exposed to simulated reentry environments and investigates the influence of microstructure and composition on the material? response. Other foam properties (mechanical and thermal) will also be presented.

Stockpoole, Mairead↗
NASA NTRS1980

An assessment of the readiness of ablative materials for preflight application to the shuttle orbiter

The shuttle orbiter relies primarily on a reusable surface insulation (RSI) thermal protection system (TPS). The RSI is very efficient in its thermal performance; however, the RSI tile system has shown poor mechanical integrity. The state-of-the-art of the ablative TPS is reviewed, and an assessment made of the ablator's readiness for use on the shuttle orbiter. Unresolved technical issues with regard to the ablative TPS are identified. Short time, highly focused analytical and experimental programs were initiated to: (1) identify candidate ablation materials; (2) assess the data base for these materials; (3) evaluate the need and kind of waterproof coating; (4) calculate thermal and other stresses in an ablator tile; (5) identify an acceptable ablator/RSI tile joint filler; and (6) assess the sensitivity of the ablator to sequential heat pulses. Results from some of these programs are discussed.

Tompkins, S. S.↗
NASA NTRS1997

Development of Processing Techniques for Advanced Thermal Protection Materials

During the period June 1, 1996 through May 31, 1997, the main effort has been in the development of materials for high temperature applications. Thermal Protection Systems (TPS) are constantly being tested and evaluated for thermal shock resistance, high temperature dimensional stability, and tolerance to environmental effects. Materials development was carried out by using many different instruments and methods, ranging from intensive elemental analysis to testing the physical attributes of a material. The material development concentrated on two key areas: (1) development of coatings for carbon/carbon composites, and (2) development of ultra-high temperature ceramics (UHTC). This report describes the progress made in these two areas of research during this contract period.

Selvaduray, Guna↗
NASA NTRS1998

Aerothermal Test of Metallic TPS for X-33 Reusable Launch Vehicle

An array of metallic Thermal Protection System (TPS) panels including the seals developed for the windward surface of the X-33 vehicle is being tested in the Eight Foot High Temperature Tunnel at the NASA Langley Research Center. These tests are the first aerothermal tests of an X-33 TPS array and will be used to validate the TPS for the X-33 flight program. Specifically, the tests will be used to evaluate the structural and thermal performance of the TPS, the effectiveness of the high temperature seals between adjacent tiles and the durability of the TPS under realistic aerothermal flight conditions. The effect of varying step heights, damage to the seals between adjacent panels, and the use of secondary seals will also be investigated during the test program. The metallic TPS developed for the windward surface of the X-33 and the test program in the Eight Foot High Temperature Tunnel is presented and discussed.

Sawyer, James Wayne↗
NASA NTRS1977

Experimental subsonic drag properties of the space shuttle orbiter TPS tiles

The drag characteristics of the space shuttle orbiter thermal protection system (TPS) tiles were studied experimentally in subsonic flow. Full-scale tiles were mounted to a 3.05 x 3.5 m test board in four configurations plus a completely smooth case. Pressure gradients were produced by tilting the board relative to the freestream. The drags due to steps, slots, and gaps between the tiles were evaluated at various orientations, pressure gradients, and Reynolds numbers. Results showed that the contribution of gaps and slots were minor compared to those of typical steps. The results for skin friction did not correlate as a fully rough surface. Thus, the surface area of the TPS tiles was sufficient to allow smooth-wall Reynolds number effects even though the steps between tiles could double the skin friction.

Norton, D. J.↗