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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 NTRS2004

Characterization of Space Shuttle External Tank Thermal Protection System (TPS) Materials in Support of the Columbia Accident Investigation

NASA suffered the loss of the seven-member crew of the Space Shuttle Columbia on February 1, 2003 when the vehicle broke apart upon re-entry to the Earth's atmosphere. The final report of the Columbia Accident Investigation Board (CAIB) determined that the accident was caused by a launch ascent incident-a suitcase-sized chunk of insulating foam on the Shuttle's External Tank (ET) broke off, and moving at almost 500 mph, struck an area of the leading edge of the Shuttle s left wing. As a result, one or more of the protective Reinforced Carbon-Carbon (RCC) panels on the wing leading edge were damaged. Upon re-entry, superheated air approaching 3,000 F breached the wing damage and caused the vehicle breakup and loss of crew. The large chunk of insulating foam that broke off during the Columbia launch was determined to come from the so-called bipod ramp area where the Shuttle s orbiter (containing crew) is attached to the ET. Underneath the foam in the bipod ramp area is a layer of TPS that is a cork-filled silicone rubber composite. In March 2003, the NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama received cured samples of the foam and composite for testing from the Michoud Assembly Facility (MAF) in New Orleans, Louisiana. The MAF is where the Shuttle's ET is manufactured. The foam and composite TPS materials for the ET have been well characterized for mechanical property data at the super-cold temperatures of the liquid oxygen and hydrogen fuels used in the ET. However, modulus data on these materials is not as well characterized. The TA Instruments 2980 Dynamic Mechanical Analyzer (DMA) was used to determine the modulus of the two TPS materials over a range of -145 to 95 C in the dual cantilever bending mode. Multi-strain, fixed frequency DMA tests were followed by multi-frequency, fixed strain tests to determine the approximate bounds of linear viscoelastic behavior for the two materials. Additional information is included in the original extended abstract.

Wingard, Charles D.↗
NASA NTRS2008

Test-Analysis Correlation for Space Shuttle External Tank Foam Impacting RCC Wing Leading Edge Component Panels

The Space Shuttle Columbia Accident Investigation Board recommended that NASA develop, validate, and maintain a modeling tool capable of predicting the damage threshold for debris impacts on the Space Shuttle Reinforced Carbon-Carbon (RCC) wing leading edge and nosecap assembly. The results presented in this paper are one part of a multi-level approach that supported the development of the predictive tool used to recertify the shuttle for flight following the Columbia Accident. The assessment of predictive capability was largely based on test analysis comparisons for simpler component structures. This paper provides comparisons of finite element simulations with test data for external tank foam debris impacts onto 6-in. square RCC flat panels. Both quantitative displacement and qualitative damage assessment correlations are provided. The comparisons show good agreement and provided the Space Shuttle Program with confidence in the predictive tool.

Lyle, Karen H.↗
NASA NTRS1977

Properties and applications of a pitch carbon microsphere composite

Some properties and applications of a pitch carbon microsphere composite are described. The small hollow microspheres are made from the pitch which is usually a wasted by-product of petroleum refining. In contrast to high density composites or syntactic foams in which microspheres are inclusions within a continuous matrix, this composite is an aggregate of microspheres bonded together by a small amount of thermosetting polymer which does not form a continuous matrix. The result is a composite with low density and thermal expansion, modest strength and rigidity, and high porosity and carbon content. Mechanical, thermal, and sorption properties have been measured. Applications of the composite include honeycomb filler for high temperature or ionizing radiation fields and a wicking absorber for solar-powered stills.

Price, H. L.↗
NASA NTRS1999

Gas Sensor Evaluations in Polymer Combustion Product Atmospheres

Toxic gases produced by the combustion or thermo-oxidative degradation of materials such as wire insulation, foam, plastics, or electronic circuit boards in space shuttle or space station crew cabins may pose a significant hazard to the flight crew. Toxic gas sensors are routinely evaluated in pure gas standard mixtures, but the possible interferences from polymer combustion products are not routinely evaluated. The NASA White Sands Test Facility (WSTF) has developed a test system that provides atmospheres containing predetermined quantities of target gases combined with the coincidental combustion products of common spacecraft materials. The target gases are quantitated in real time by infrared (IR) spectroscopy and verified by grab samples. The sensor responses are recorded in real time and are compared to the IR and validation analyses. Target gases such as carbon monoxide, hydrogen cyanide, hydrogen chloride, and hydrogen fluoride can be generated by the combustion of poly(vinyl chloride), polyimide-fluoropolymer wire insulation, polyurethane foam, or electronic circuit board materials. The kinetics and product identifications for the combustion of the various materials were determined by thermogravimetric-IR spectroscopic studies. These data were then scaled to provide the required levels of target gases in the sensor evaluation system. Multisensor toxic gas monitors from two manufacturers were evaluated using this system. In general, the sensor responses satisfactorily tracked the real-time concentrations of toxic gases in a dynamic mixture. Interferences from a number of organic combustion products including acetaldehyde and bisphenol-A were minimal. Hydrogen bromide in the products of circuit board combustion registered as hydrogen chloride. The use of actual polymer combustion atmospheres for the evaluation of sensors can provide additional confidence in the reliability of the sensor response.

Delgado, Rafael H.↗
NASA NTRS2017

Shape Effect Analysis of Aluminum Projectile Impact on Whipple Shields

The informed design with respect to hypervelocity collisions involving micrometeoroid and orbital debris (MMOD) is influential to the success of space missions. For an orbit comparable to that of the International Space Station, velocities for MMOD can range from 1 to 15 km/s, with an average velocity around 10 km/cu s. The high energy released during collisions at these speeds can result in damage to a spacecraft, or worst-case, loss of the spacecraft, thus outlining the importance of methods to predict the likelihood and extent of damage due to an impact. Through experimental testing and numerical simulations, substantial work has been conducted to better understand the effects of hypervelocity impacts (HVI) on spacecraft systems and shields; however, much of the work has been focused on spherical impacting particles. To improve environment models for the analysis of MMOD, a large-scale satellite break-up test was performed at the Arnold Engineering and Development Complex to better understand the varied impactor geometries that could be generated from a large impact. As a part of the post-experiment analysis, an undertaking to characterize the irregular fragments generated is currently being performed by the University of Florida under the management of NASA's Orbital Debris Program Office at Johnson Space Center (JSC). DebriSat was a representative, modern LEO satellite that was catastrophically broken up in a HVI test. The test chamber was lined with a soft-catch system of foam panels that captured the fragments after impact. Initial predictions put the number of fragments larger than 2mm generated from the HVI at roughly 85,000. The number of fragments thus far extracted from the foam panels has exceeded 100,000, with that number continuously increasing. The shapes of the fragments vary dependent upon the material. Carbon-fiber reinforced polymer pieces, for instance, are abundantly found as thin, flat slivers. The characterization of these fragments with respect to their mass, size, and material composition needs to be summarized in a form that can be used in MMOD analysis. The mechanism that brings these fragment traits into MMOD analysis is through ballistic limit equations (BLE) that have been developed largely for a few types of materials1. As a BLE provides the failure threshold for a shield or spacecraft component based on parameters such as the projectile impact velocity and size, and the target's materials, thickness, and configuration, it is used to design protective shields for spacecraft such as Whipple shields (WS) to an acceptable risk level. The majority of experiments and simulations to test shields and validate BLEs have, heretofore, largely used spheres as the impactor, not properly reflecting the irregular shapes of MMOD. This shortfall has motivated a numerical impact analysis study of HVI involving non-spherical geometries to identify key parameters that environment models should provide.

Carrasquilla, Maria J.↗
NASA NTRS2005

STS-114: Discovery Post MMT Briefing

Wayne Hale, Space Shuttle Deputy Program Manager and Steve Poulos, Manager Orbit Project Office at Johnson Space Center is seen during a post Mission Management Team (MMT) briefing. The purpose of this briefing is to talk about the status of the Space Shuttle Discovery Orbiter, the Thermal Protection System (TPS) and the External Tank. Hale presents pictures of the missing foam off of the Hydrogen Protuberance Air Load (PAL) ramp and trajectory debris particles. Poulos explains in detail diagrams of the reinforced carbon-carbon system, possible scuff on the wing panel, coating damage, protruding gap filler and damaged tile blanket. Poulos tells what concerns him the most in terms of tile damage to the Space Shuttle Discovery.

Source record↗
NASA NTRS1996

Analysis and Tests of Reinforced Carbon-Epoxy/Foam-Core Sandwich Panels with Cutouts

The results of a study of a low-cost structurally efficient minimum-gage shear-panel design that can be used in light helicopters are presented. The shear-panel design is based on an integrally stiffened syntactic-foam stabilized-skin with an all-bias-ply tape construction for stabilized-skin concept with an all-bias-ply tape construction for the skins. This sandwich concept is an economical way to increase the panel bending stiffness weight penalty. The panels considered in the study were designed to be buckling resistant up to 100 lbs/in. of shear load and to have an ultimate strength of 300 lbs/in. The panel concept uses unidirectional carbon-epoxy tape on a syntactic adhesive as a stiffener that is co-cured with the skin and is an effective concept for improving panel buckling strength. The panel concept also uses pultruded carbon-epoxy rods embedded in a syntactic adhesive and over-wrapped with a bias-ply carbon-epoxy tape to form a reinforcing beam which is an effective method for redistributing load around rectangular cutout. The buckling strength of the reinforced panels is 83 to 90 percent of the predicted buckling strength based on a linear buckling analysis. The maximum experimental deflection exceeds the maximum deflection predicted by a nonlinear analysis by approximately one panel thickness. The failure strength of the reinforced panels was two and a half to seven times of the buckling strength. This efficient shear-panel design concept exceeds the required ultimate strength requirement of 300 lbs/in by more than 100 percent.

Baker, Donald J.↗
NASA NTRS1979

Transfer functions

The vulnerability of electronic equipment to carbon fibers is studied. The effectiveness of interfaces, such as filters, doors, window screens, and cabinets, which affect the concentration, exposure, or deposition of carbon fibers on both (internal and external) sides of the interface is examined. The transfer function of multilayer aluminum mesh, wet and dry, polyurethane foam, and window screen are determined as a function of air velocity. FIlters installed in typical traffic control boxes and air conditioners are also considered.

Taback, I.↗
NASA NTRS1983

Structures and subsystems

New and improved materials combined with efficient structural design concepts have made an essential contribution towards the shaping of the present transportation system (STS), and now, for the replacement of the STS in the year 2005, new materials and novel designs are being studied to identify the technologies which should be developed for a low-cost future space transportation system (FSTS). Three basic structural arrangements were considered for the FSTS orbiter. They include a nonintegral tank arrangement, an integral-tank arrangement, and a hybrid of the first two. Three representative arrangements regarding wall constructions are considered. Each employs a blade-stiffened aluminum tank with reinforced closed-cell-foam cryogenic insulation. Attention is given to an aluminum-alloy structure, a graphite-epoxy structure, a graphite-polyimide structure, a carbon-carbon surface panel structure, a graphite-composite fuselage structure, serviceability and all-weather considerations, and structural concept ratings.

Taylor, A. H.↗
NASA NTRS2004

Acoustic Emission Detection of Impact Damage on Space Shuttle Structures

The loss of the Space Shuttle Columbia as a result of impact damage from foam debris during ascent has led NASA to investigate the feasibility of on-board impact detection technologies. AE sensing has been utilized to monitor a wide variety of impact conditions on Space Shuttle components ranging from insulating foam and ablator materials, and ice at ascent velocities to simulated hypervelocity micrometeoroid and orbital debris impacts. Impact testing has been performed on both reinforced carbon composite leading edge materials as well as Shuttle tile materials on representative aluminum wing structures. Results of these impact tests will be presented with a focus on the acoustic emission sensor responses to these impact conditions. These tests have demonstrated the potential of employing an on-board Shuttle impact detection system. We will describe the present plans for implementation of an initial, very low frequency acoustic impact sensing system using pre-existing flight qualified hardware. The details of an accompanying flight measurement system to assess the Shuttle s acoustic background noise environment as a function of frequency will be described. The background noise assessment is being performed to optimize the frequency range of sensing for a planned future upgrade to the initial impact sensing system.

Prosser, William H.↗
NASA NTRS2006

Test and Analysis of Foam Impacting a 6x6 Inch RCC Flat Panel

This report presents the testing and analyses of a foam projectile impacting onto thirteen 6x6 inch flat panels at a 90 degrees incidence angle. The panels tested in this investigation were fabricated of Reinforced-Carbon-Carbon material and were used to aid in the validation of an existing material model, MAT58. The computational analyses were performed using LS-DYNA, which is a physics-based, nonlinear, transient, finite element code used for analyzing material responses subjected to high impact forces and other dynamic conditions. The test results were used to validate LS-DYNA predictions and to determine the threshold of damage generated by the MAT58 cumulative damage material model. The threshold of damage parameter represents any external or internal visible RCC damage detectable by nondestructive evaluation techniques.

Lessard, Wendy B.↗
NASA NTRSDate not supplied

Nondestructive Evaluation for the Space Shuttle's Wing Leading Edge

The loss of the Space Shuttle Columbia highlighted concerns about the integrity of the Shuttle's thermal protection system, which includes Reinforced Carbon-Carbon (RCC) on the leading edge. This led NASA to investigate nondestructive evaluation (NDE) methods for certifying the integrity of the Shuttle's wing leading edge. That investigation was performed simultaneously with a large study conducted to understand the impact damage caused by errant debris. Among the many advanced NDE methods investigated for applicability to the RCC material, advanced digital radiography, high resolution computed tomography, thermography, ultrasound, acoustic emission and eddy current systems have demonstrated the maturity and success for application to the Shuttle RCC panels. For the purposes of evaluating the RCC panels while they are installed on the orbiters, thermographic detection incorporating principal component analysis (PCA) and eddy current array scanning systems demonstrated the ability to measure the RCC panels from one side only and to detect several flaw types of concern. These systems were field tested at Kennedy Space Center (KSC) and at several locations where impact testing was being conducted. Another advanced method that NASA has been investigating is an automated acoustic based detection system. Such a system would be based in part on methods developed over the years for acoustic emission testing. Impact sensing has been demonstrated through numerous impact tests on both reinforced carbon-carbon (RCC) leading edge materials as well as Shuttle tile materials on representative aluminum wing structures. A variety of impact materials and conditions have been evaluated including foam, ice, and ablator materials at ascent velocities as well as simulated hypervelocity micrometeoroid and orbital debris impacts. These tests have successfully demonstrated the capability to detect and localize impact events on Shuttle's wing structures. A first generation impact sensing system has been designed for the next Shuttle flight and is undergoing final evaluation for deployment on the Shuttle's first return to flight. This system will employ wireless accelerometer sensors that were qualified for other applications on previous Shuttle flights. These sensors will be deployed on the wing's leading edge to detect impacts on the RCC leading edge panels. The application of these methods will help to insure the continued integrity of the Shuttle wing's leading edge system as the Shuttle flights resume and until their retirement.

Eric I Madaras↗
NASA NTRS2004

Comparison of Carbon Dioxide and Helium as Fire Extinguishing Agents for Spacecraft

The effects of radiation heat transfer in microgravity compared to convection heat transfer in earth gravity for opposed-flow (downward) over thermally-thick fuel using low density foam fuel were investigated. Microgravity experiments on flame spread over thermally-thick fuels were conducted using foam fuels to obtain low density and thermal conductivity, and thus large flame spread rate compared to dense fuels such as PMMA. And thereby valid microgravity results were obtained even in 2.2 second drop-tower experiments not to mention for the longer duration tests in Zero Gravity Facility. Contrast to the conventional understanding, it was found that steady flame spread can occur over thick fuels in quiescent microgravity environments, especially when radiatively-active diluent gases such as CO2 were employed. This is proposed to result from radiative heat transfer from the flame to the fuel surface, which could lead to steady spread even when the amount of the heat transfer via conduction from the flame to the fuel bed is negligible. Radiative effects are more significant at microgravity conditions because the flame is thicker and thus the volume of radiating combustion products is larger as well. These results suggested that helium may be a better inert or extinguishment agent on both a mass and a mole bases at microgravity even though CO2 is much better on a mole bases at earth gravity, and these are relevant to studies of fire safety in manned spacecraft, particularly the International Space Station that uses CO2 fire extinguishers. CO2 may not be as effective as an extinguishing agent at g as it is at earth gravity in some conditions because of the differences in spread mechanisms between the two cases. In particular, the difference between conduction-dominated heat transport to the fuel bed at earth gravity and radiation-dominated heat transport at g indicates that radiatively-inert diluent such as helium could be preferable in g applications. Helium may be a superior fire suppression agent at g on several bases. First, helium is more effective than CO2 on a mole basis (thus pressure times storage volume basis) at g, meaning that the size and weight of storage bottles would be smaller for the same fire-fighting capability. Second; helium is much more effective on a mass basis (by about 11 times) at g. Third; helium has no physiological activity, unlike CO2 that affects human respiration. Fourth, as compared to N2 or CO2, is not very soluble in water and thus has fewer tendencies to cause bloodstream bubble formation following rapid spacecraft cabin depressurization.

Gokoglu, Suleyman↗
NASA NTRS2004

Comparison of Carbon Dioxide and Helium as Fire Extinguishing Agents for Spacecraft

The effects of radiation heat transfer in microgravity compared to convection heat transfer in earth gravity for opposed-flow (downward) over thermally-thick fuel using low density foam fuel were investigated. Microgravity experiments on flame spread over thermally-thick fuels were conducted using foam fuels to obtain low density and thermal conductivity, and thus large flame spread rate compared to dense fuels such as PMMA. And thereby valid microgravity results were obtained even in 2.2 second drop-tower experiments not to mention for the longer duration tests in Zero Gravity Facility. Contrast to the conventional understanding, it was found that steady flame spread can occur over thick fuels in quiescent microgravity environments, especially when radiatively-active diluent gases such as CO2 were employed. This is proposed to result from radiative heat transfer from the flame to the fuel surface, which could lead to steady spread even when the amount of the heat transfer via conduction from the flame to the fuel bed is negligible. Radiative effects are more significant at microgravity conditions because the flame is thicker and thus the volume of radiating combustion products is larger as well. These results suggested that helium may be a better inert or extinguishment agent on both a mass and a mole bases at microgravity even though CO2 is much better on a mole bases at earth gravity, and these are relevant to studies of fire safety in manned spacecraft, particularly the International Space Station that uses CO2 fire extinguishers. CO2 may not be as effective as an extinguishing agent at microgravity as it is at earth gravity in some conditions because of the differences in spread mechanisms between the two cases. In particular, the difference between conduction-dominated heat transport to the fuel bed at earth gravity and radiation-dominated heat transport at microgravity indicates that radiatively-inert diluent such as helium could be preferable in microgravity applications. Helium may be a superior fire suppression agent at microgravity on several bases. First, helium is more effective than CO2 on a mole basis (thus pressure times storage volume basis) at microgravity, meaning that the size and weight of storage bottles would be smaller for the same fire-fighting capability. Second; helium is much more effective on a mass basis (by about 11 times) at microgravity. Third; helium has no physiological activity, unlike CO2 that affects human respiration. Fourth, as compared to N2 or CO2, is not very soluble in water and thus has fewer tendencies to cause bloodstream bubble formation following rapid spacecraft cabin depressurization.

Gokoglu, Suleyman↗
NASA NTRS2005

Dynamics Impact Tolerance of Shuttle RCC Leading Edge Panels Using LS-DYNA

This paper describes a research program conducted to enable accurate prediction of the impact tolerance of the shuttle Orbiter leading-edge wing panels using physics-based codes such as LS-DYNA, a nonlinear, explicit transient dynamic finite element code. The shuttle leading-edge panels are constructed of Reinforced-Carbon-Carbon (RCC) composite material, which is used because of its thermal properties to protect the shuttle during reentry into the Earth's atmosphere. Accurate predictions of impact damage from insulating foam and other debris strikes that occur during launch required materials characterization of expected debris, including strain-rate effects. First, analytical models of individual foam and RCC materials were validated. Next, analytical models of foam cylinders impacting 6- in. x 6-in. RCC flat plates were developed and validated. LS-DYNA pre-test models of the RCC flat plate specimens established the impact velocity of the test for three damage levels: no-detectable damage, non-destructive evaluation (NDE) detectable damage, or visible damage such as a through crack or hole. Finally, the threshold of impact damage for RCC on representative Orbiter wing panels was predicted for both a small through crack and for NDE-detectable damage.

Fasanella, Edwin L.↗
NASA NTRS2008

Dynamic Impact Tolerance of Shuttle RCC Leading Edge Panels using LS-DYNA

This paper describes a research program conducted to enable accurate prediction of the impact tolerance of the shuttle Orbiter leading-edge wing panels using 'physics-based- codes such as LS-DYNA, a nonlinear, explicit transient dynamic finite element code. The shuttle leading-edge panels are constructed of Reinforced-Carbon-Carbon (RCC) composite material, which issued because of its thermal properties to protect the shuttle during re-entry into the Earth's atmosphere. Accurate predictions of impact damage from insulating foam and other debris strikes that occur during launch required materials characterization of expected debris, including strain-rate effects. First, analytical models of individual foam and RCC materials were validated. Next, analytical models of individual foam cylinders impacting 6-in. x 6-in. RCC flat plates were developed and validated. LS-DYNA pre-test models of the RCC flat plate specimens established the impact velocity of the test for three damage levels: no-detectable damage, non-destructive evaluation (NDE) detectable damage, or visible damage such as a through crack or hole. Finally, the threshold of impact damage for RCC on representative Orbiter wing panels was predicted for both a small through crack and for NDE-detectable damage.

Fasanella, Edwin↗
NASA NTRS1985

Design of an experiment for the production of a foamed tin sample

The purpose of this paper is to present to fellow GAS users a portion of Purdue University's efforts. One of the major experiments in our GAS container is concerned with the experimental production of a foamed metal. A foamed metal is one that contains a significant amount of gas bubbles suspended in its solid volume. Purdue's GAS team proposes to do this with the help of a solid zinc carbonate that gives off carbon dioxide at high temperatures. Because of low energy requirements, the metal used for this experiment is tin. It is hoped that the use of near zero environment will keep the suspended bubbles more uniform than in an earth based process, hence not depleting the physical strength of the material as greatly as is observed on earth.

Eric Wernimont↗
NASA NTRS2015

Multi-Level Experimental and Analytical Evaluation of Two Composite Energy Absorbers

Two composite energy absorbers were developed and evaluated at NASA Langley Research Center through multi-level testing and simulation performed under the Transport Rotorcraft Airframe Crash Testbed (TRACT) research program. A conical-shaped energy absorber, designated the conusoid, was evaluated that consisted of four layers of hybrid carbon-Kevlar plain weave fabric oriented at [+45 deg/-45 deg/-45 deg/+45 deg] with respect to the vertical, or crush, direction. A sinusoidal-shaped energy absorber, designated the sinusoid, was developed that consisted of hybrid carbon-Kevlar plain weave fabric face sheets, two layers for each face sheet oriented at +/-45deg with respect to the vertical direction and a closed-cell ELFOAM P200 polyisocyanurate (2.0-lb/cu ft) foam core. The design goal for the energy absorbers was to achieve average floor-level accelerations of between 25- and 40-g during the full-scale crash test of a retrofitted CH-46E helicopter airframe, designated TRACT 2. Variations in both designs were assessed through dynamic crush testing of component specimens. Once the designs were finalized, subfloor beams of each configuration were fabricated and retrofitted into a barrel section of a CH-46E helicopter. A vertical drop test of the barrel section was conducted onto concrete to evaluate the performance of the energy absorbers prior to retrofit into TRACT 2. The retrofitted airframe was crash tested under combined forward and vertical velocity conditions onto soil, which is characterized as a sand/clay mixture. Finite element models were developed of all test articles and simulations were performed using LS-DYNA, a commercial nonlinear explicit transient dynamic finite element code. Test-analysis results are presented for each energy absorber as comparisons of time-history responses, as well as predicted and experimental structural deformations and progressive damage under impact loading for each evaluation level.

Jackson, Karen E.↗