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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.↗

NASA NTRS1980

Shuttle subscale ablative nozzle tests

Recent subscale nozzle tests have identified new and promising carbon phenolic nozzle ablatives which utilize staple rayon, PAN, and pitch based carbon cloth. A 4-inch throat diameter submerged test nozzle designed for the 48-inch Jet Propulsion Laboratory char motor was used to evaluate five different designs incorporating 20 candidate ablatives. Test results indicate that several pitch and PAN-based carbon phenolic ablatives can provide erosion and char performance equivalent or superior to the present continuous rayon-based SRM ablative.

Powers, L. B.↗

NASA NTRS1976

Nozzle designs with pitch precursor ablatives

Recent developments in carbon phenolic ablatives for solid rocket motor nozzles have yielded a pitch precursor carbon fiber offering significant raw material availability and cost saving advantages as compared to conventional rayon precursor material. This paper discusses the results of an experimental program conducted to assess the thermal performance and characterize the thermal properties of pitch precursor carbon phenolic ablatives. The end result of this program is the complete thermal characterization of pitch fabric, pitch mat, hybrid pitch/rayon fabric and pitch mat molding compound. With these properties determined an analytic capability now exists for predicting the thermal performance of these materials in rocket nozzle liner applications. Further planned efforts to verify material performance and analytical prediction procedures through actual rocket motor firings are also discussed.

Blevins, H. R.↗

NASA NTRS1983

Stagnation-point ablation of carbonaceous flat disks. I Theory

The process of ablation is calculated for the stagnation region of a flat disk in a radiation-dominated, massive-blowing environment produced in a ballistic range filled with argon. Flow environments are determined by solving the boundary-layer equations while radiative transfer is calculated through a line-by-line spectral computation. The resulting wall heat-transfer rates are coupled with an existing material's response code to determine surface recession and char thickness. The calculation is performed for six 5-cm-diam models made of carbon-phenolic and carbon-carbon composite launched in the Track-G facility at the Arnold Engineering Development Center. Significant surface recessions are predicted to occur for these models due mostly to radiative heating.

Park, C.↗

NASA NTRS1997

TPS Materials for Planetary Exploration

This paper will review the current material options, and near term developments, for thermal protection systems (TPS) of future space craft involving atmospheric entry. TPS is a very important element in the design of these vehicles, and can have large impact on the project risk and cost. The new family of light weight ceramic ablators illustrated by SIRCA and PIC will be discussed, along with state-of-the-art ablators including SLA-561V, Avcoat-5026, carbon-phenolic, and carbon-carbon.

Rasky, Daniel J.↗

NASA NTRS2014

Woven Thermal Protection System (WTPS) a Novel Approach to Meet Nasa's Most Demanding Reentry Missions

NASA's future robotic missions to Venus and other planets, namely, Saturn, Uranus, Neptune, result in extremely high entry conditions that exceed the capabilities of current mid density ablators (PICA or Avcoat). Therefore mission planners assume the use of a fully dense carbon phenolic heatshield similar to what was flown on Pioneer Venus and Galileo. Carbon phenolic is a robust TPS, however, its high density and thermal conductivity constrain mission planners to steep entries, high fluxes, pressures and short entry durations, in order for CP to be feasible from a mass perspective. The high entry conditions pose certification challenges in existing ground based test facilities. In 2012 the Game Changing Development Program in NASA's Space Technology Mission Directorate funded NASA ARC to investigate the feasibility of a Woven Thermal Protection System to meet the needs of NASA's most challenging entry missions. This presentation will summarize the maturation of the WTPS project.

thermal protection↗

NASA NTRS2013

Woven Thermal Protection System Based Heat-shield for Extreme Entry Environments Technology (HEEET)

NASA's future robotic missions utilizing an entry system into Venus and the outer planets, namely, Saturn, Uranus, Neptune, result in extremely severe entry conditions that exceed the capabilities of state of the art low to mid density ablators such as PICA or Avcoat. Therefore mission planners typically assume the use of a fully dense carbon phenolic heat shield similar to what was flown on Pioneer Venus and Galileo. Carbon phenolic (CP) is a robust TPS material however its high density and relatively high thermal conductivity constrain mission planners to steep entries, with high heat fluxes and pressures and short entry durations, in order for CP to be feasible from a mass perspective. The high entry conditions pose challenges for certification in existing ground based test facilities and the longer-‐term sustainability of CP will continue to pose challenges. In 2012 the Game Changing Development Program (GCDP) in NASA's Space Technology Mission Directorate funded NASA ARC to investigate the feasibility of a Woven Thermal Protection System (WTPS) to meet the needs of NASA's most challenging entry missions. This project was highly successful demonstrating that a Woven TPS solution compares favorably to CP in performance in simulated reentry environments and provides the opportunity to manufacture graded materials that should result in overall reduced mass solutions and enable a much broader set of missions than does CP. Building off the success of the WTPS project GCDP has funded a follow on project to further mature and scale up the WTPS concept for insertion into future NASA robotic missions. The matured WTPS will address the CP concerns associated with ground based test limitations and sustainability. This presentation will briefly discuss results from the WTPS Project and the plans for WTPS maturation into a heat-‐shield for extreme entry environment.

Chinnapongse, Ronald↗

NASA NTRS2013

Woven Thermal Protection System Based Heat-shield for Extreme Entry Environments Technology (HEEET)

NASA's future robotic missions utilizing an entry system into Venus and the outer planets, namely, Saturn, Uranus, Neptune, result in extremely high entry conditions that exceed the capabilities of state of the art low to mid density ablators such as PICA or Avcoat. Therefore mission planners typically assume the use of a fully dense carbon phenolic heat shield similar to what was flown on Pioneer Venus and Galileo. Carbon phenolic is a robust TPS material however its high density and relatively high thermal conductivity constrain mission planners to steep entries, with high heat fluxes and pressures and short entry durations, in order for CP to be feasible from a mass perspective. The high entry conditions pose challenges for certification in existing ground based test facilities and the longer‐term sustainability of CP will continue to pose challenges. In 2012 the Game Changing Development Program (GCDP) in NASA's Space Technology Mission Directorate funded NASA ARC to investigate the feasibility of a Woven Thermal Protection System (WTPS) to meet the needs of NASA's most challenging entry missions. This project was highly successful demonstrating that a Woven TPS solution compares favorably to CP in performance in simulated reentry environments and provides the opportunity to manufacture graded materials that should result in overall reduced mass solutions and enable a much broader set of missions than does CP. Building off the success of the WTPS project GCDP has funded a follow on project to further mature and scale up the WTPS concept for insertion into future NASA robotic missions. The matured WTPS will address the CP concerns associated with ground based test limitations and sustainability. This presentation will briefly discuss results from the WTPS Project and the plans for WTPS maturation into a heat‐shield for extreme entry environment.

Ellerby, Donald↗

NASA NTRS2016

Heatshield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASAs high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50 mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in its 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

Thermal Protection System↗

NASA NTRS2016

Heat-shield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASA's high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50% mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in it's 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to-date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

TPS↗

NASA NTRS1983

Stagnation-point ablation of carbonaceous flat disks. II Experiment

Six flat-disk models made of carbon-carbon and carbon-phenolic materials were launched in an argon-filled track-range facility to test ablation characteristics in a radiation-dominated, massive-blowing environment. The shock standoff distances deduced from the shadowgraphs agree with theoretical predictions during the earlier portion of the flight, while the wall temperatures determined by the image-converter photographs agree with predictions during the later portion. The measured surface recessions exceed the calculated values by about 60 percent for carbon-phenolic and 30 percent for carbon-carbon. The discrepancies are attributed to spallation. The measured char thicknesses agree with theoretical predictions.

Park, C.↗

NASA NTRS1976

Heat shield characterization: Outer planet atmospheric entry probe

A full scale carbon phenolic heat shield was fabricated for the Outer Planet Probe in order to demonstrate the feasibility of molding large carbon phenolic parts with a new fabrication processing method (multistep). The sphere-cone heat shield was molded as an integral unit with the nose cap plies configured into a double inverse chevron shape to achieve the desired ply orientation. The fabrication activity was successful and the feasibility of the multistep processing technology was established. Delaminations or unbonded plies were visible on the heat shield and resulted from excessive loss of resin and lack of sufficient pressure applied on the part during the curing cycle. A comprehensive heat shield characterization test program was conducted, including: nondestructive tests with the full scale heat shield and thermal and mechanical property tests with small test specimen.

Mezines, S. A.↗

NASA NTRS2019

Challenges in Qualification of Thermal Protection Systems in Extreme Entry Environments

Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heat shield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heat shield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heat shield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (>2000 W/sq. cm heat flux and >2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heat shield for Extreme Entry Environments (HEEET). Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions. Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions. Examples include: (1) Bounding aeroheating parameters (heat flux, pressure, shear and enthalpy) in ground facilities. How to certify TPS if environments can't be bounded or aeroheating parameters can't be simultaneously achieved. (2) Higher uncertainties in ground test environments (facility calibration and analytical predictions) at extreme conditions. (3) Testing in flows similar to planetary atmosphere composition (H2/He for Gas and Ice Giants). (4) Test sample size limitations for qualifying seam designs. (5) Lack of computational tools capable of simulating all significant aspects of TPS performance (including initiation and propagation of failures). This presentation will provide recommendations on how the EDL community can address these challenges and mitigate some of the risks involved in flying TPS materials at extreme conditions. Examples include: (1) Dedicated activity to understanding TPS failure modes. Develop computational tools capable of modelling fluid interaction with material's thermostructural response. Validate these tools through failure testing. A better understanding of failure mechanisms may eliminate the need to fully bound all aeroheating parameters in ground testing. (2) Enhancements to current testing facilities to simulate flight-like ablation mechanism (ex. testing in Nitrogen at Ames Interaction Heating Facility to limit oxidation in favor of more sublimation). (3) Improved characterization of test conditions with new diagnostic methods and determination of environment uncertainty through rigorous statistical analysis of available data. (4) Design margin policies that are directly tied to uncertainties in ground test environments and modelling fidelity

Mahzari, Milad↗

NASA NTRS2019

Challenges in Qualification of Thermal Protection Systems for Extreme Entry Environments

Mahzari, Milad↗

NASA NTRS2020

Technologies for Future Venus Exploration

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

Thermal Protection Systems↗

NASA NTRS2006

Real-Time Radiographic In-Situ Characterization Of Ply Lift In Composite Aerospace Materials

The problem of ply lifting in composite materials is a significant issue for various aerospace and military applications. A fundamental element in the prevention or mitigation of ply lift is determination of the timing of the ply lifting event during exposure of the composite material to flight conditions. The Marshall Space Flight Center s Nondestructive Evaluation Team developed a real-time radiographic technique for the detection of ply lift in carbon phenolic ablative materials in situ during live firings of subscale test motors in support of NASA s Reusable Solid Rocket Motor program, using amorphous silicon detector panels. The radiographic method has successfully detected ply lifting in seven consecutive carbon phenolic converging cones attached to solid fuel torches, providing the time of ply lift initiation in each test. Post-processing of the radiographic images improved the accuracy of timing measurements and allowed measurement of the ply lifting height as a function of time. Radiographic data correlated well with independent pressure and temperature measurements that indicate the onset of ply lift in the nozzle material.

Beshears, Ronald D.↗

NASA NTRSDate not supplied

Rocket Lab Venus - Enabling Low-Cost Interplanetary Missions

Rocket Lab’s mission to Venus, launching in January 2025, aims to demonstrate that small launch vehicles, such as Electron, and high-energy small spacecraft, such as Photon, can enable a new paradigm of regular, low-cost interplanetary missions. The primary science mission involves a small ~20 kg direct entry probe that will sample the Venusian cloud layers with an autofluorescing nephelomoeter. The entry probe thermal protection system (TPS) is even more critical than usual due to the selected entry trajectory and the lack of suitable heritage TPS materials. NASA’s newly developed 3D Woven Carbon Phenolic, a derivative of the Heatshield for Extreme Entry Environment Technology (HEEET) material, is an enabling technology for this mission, and it will comprise the probe forebody heat shield. The work that led to the selection of 3D Woven Carbon Phenolic, the TPS cost-reduction approaches taken, and the future possibilities of such an approach to probe development are presented.

Lyle Campbell↗

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.↗