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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Thermal Protection System Aerothermal Screening Tests in HYMETS Facility

The Entry, Descent, and Landing (EDL) Technology Development Project has been tasked to develop Thermal Protection System (TPS) materials for insertion into future Mars Entry Systems. A screening arc jet test of seven rigid ablative TPS material candidates was performed in the Hypersonic Materials Environmental Test System (HYMETS) facility at NASA Langley Research Center, in both an air and carbon dioxide test environment. Recession, mass loss, surface temperature, and backface thermal response were measured for each test specimen. All material candidates survived the Mars aerocapture relevant heating condition, and some materials showed a clear increase in recession rate in the carbon dioxide test environment. These test results supported subsequent down-selection of the most promising material candidates for further development.

thermal protection systems (TPS)↗
NASA NTRSDate not supplied

Material Response Analysis of PICA-NuSil at the Hypersonic Materials Environmental Test System

Phenolic impregnated carbon ablator (PICA) is a thermal protection system (TPS) that gained heritage during the Stardust mission and is the baseline TPS material for expeditions to Mars (e.g., Mars Science Laboratory and Mars 2020).1 PICA is friable; therefore, a polysiloxane resin (NuSil CV-1144-0) is deposited onto the surface of flight hardware before assembly, test, and launch operations (ATLO) to mitigate particle shedding. Furthermore, the Mars Science Laboratory (MSL) and Mars 2020 heatshields were instrumented with an array of thermocouple plugs (MEDLI Integrated Sensor Plugs or MISP) designed to measure the in-depth thermal response of PICA during flight. Post-flight analysis of MISP data suggests that recession was lower than predicted, and NuSil is suspected as a reasonable cause. NuSil primarily consists of a copolymer blend of dimethyl and diphenyl-substituted polysiloxane resin. Four decades of research in the field of polymer-derived ceramics demonstrate that polysiloxane resins form oxidation-resistant silicon oxycarbide materials at pyrolysis temperatures as low as 800 °C. -2 Furthermore, silicon oxycarbide materials exhibit excellent thermal stability at relatively high-temperatures (< 1200 °C) but eventually decompose via carbothermal reduction. -3 Therefore, it is reasonable to suggest that NuSil forms an oxidation-resistant thermal barrier coating on the TPS surface and influences the material response during atmospheric entry. Evidence for this notion was observed during prior arc-jet testing at both the Aerodynamic Heating Facility (AHF) and the Panel Test Facility (PTF) at the NASA Ames Research Center. Articles of PICA were subjected to testing in airflow, and a temperature discontinuity was recorded at the surface of coupons coated with NuSil. A glassy coating was observed to form at the surface in shear flow configurations (wedge and panel) under moderate heat fluxes. Furthermore, state-of-the-art material response models have yet to account for the underlying physics and chemistry of the temperature discontinuity. To this end, a pathfinder test campaign was executed at the Hypersonic Materials Environmental Test System (HyMETS) to enhance the fundamental understanding of PICA-NuSil ablation phenomena and provide a preliminary data set to aid in the development of material response models.

PICA↗
NASA NTRS2012

Photogrammetric recession measurements of an ablating surface

An instrument and method for measuring the time history of recession of an ablating surface of a test article during testing in a high enthalpy thermal test facility, such as an arcjet. The method advances prior art by providing time-history data over the full ablating surface without targets and without any modifications to the test article. The method is non-intrusive, simple to implement, requires no external light source, and does not interfere with normal operations of the arcjet facility.

Schairer, Edward T.↗
NASA NTRS2012

Characterization of Material Response During Arc-Jet Testing with Optical Methods Status and Perspectives

The characterization of ablation and recession of heat shield materials during arc jet testing is an important step towards understanding the governing processes during these tests and therefore for a successful extrapolation of ground test data to flight. The behavior of ablative heat shield materials in a ground-based arc jet facility is usually monitored through measurement of temperature distributions (across the surface and in-depth), and through measurement of the final surface recession. These measurements are then used to calibrate/validate materials thermal response codes, which have mathematical models with reasonably good fidelity to the physics and chemistry of ablation, and codes thus calibrated are used for predicting material behavior in flight environments. However, these thermal measurements only indirectly characterize the pyrolysis processes within an ablative material pyrolysis is the main effect during ablation. Quantification of pyrolysis chemistry would therefore provide more definitive and useful data for validation of the material response codes. Information of the chemical products of ablation, to various levels of detail, can be obtained using optical methods. Suitable optical methods to measure the shape and composition of these layers (with emphasis on the blowing layer) during arc jet testing are: 1) optical emission spectroscopy (OES) 2) filtered imaging 3) laser induced fluorescence (LIF) and 4) absorption spectroscopy. Several attempts have been made to optically measure the material response of ablative materials during arc-jet testing. Most recently, NH and OH have been identified in the boundary layer of a PICA ablator. These species are suitable candidates for a detection through PLIF which would enable a spatially-resolved characterization of the blowing layer in terms of both its shape and composition. The recent emission spectroscopy data will be presented and future experiments for a qualitative and quantitative characterization of the material response of ablative materials during arc-jet testing will be discussed.

Winter, Michael↗
NASA NTRS1972

Effect of thermally expanding surfaces on aerodynamic roll torques for cones.

An experimental and analytical study has been made of the aerodynamic roll torque on smoothly ablating, spinning cones. The tests, conducted in the Ames 3.5-Foot Hypersonic Wind Tunnel, indicated that the smoothly ablating model rolling at 0 deg angle of attack experiences roll damping, but when rolling at angle of attack an aerodynamic torque in the direction of spin arises if thermal expansion of the body surface occurs. An analysis of the spinning body at angle of attack is included to show how the relative importance of the ablator thermal expansion and the surface recession rate determines whether the motion is damped or undamped.

Mcdevitt, J. B.↗
NASA NTRS1978

Carbonaceous materials subjected to extreme heating - A comparison of numerical simulation and experiments

The ablation of carbonaceous materials in a hydrogen-helium stream has been simulated using a charring materials ablator computer code. These results are compared with the first ablation data to be obtained from the Ames-NASA Giant Planet Pilot Facility. Test stream diagnostics and ablation effects on convective and radiative heat transfer are discussed since these parameters constitute important input data to the numerical simulation. Graphite ablation was predicted to within 10 to 20%, and carbon-phenolic somewhat less accurately.

Davy, W. C.↗
NASA NTRS2018

Testing with the Laser-Enhanced Arc Jet Facility (LEAF) at NASA Ames Research Center

NASA's new Laser-Enhanced Arcjet Facility (LEAF) employs 200 kilowatts of continuous-wave fiber lasers, combined with a 60-megawatt arc plasma jet, to simulate the combined radiative and convective heating is now operational and Orion heat-shield material is undergoing testing. This upgrade to the existing Interaction Heating Facility (IHF) involves the addition of high-power fiber lasers that project 1070nm radiative energy into the existing vacuum chamber. The optically expanded laser beam enters a side window of the test chamber to form either a uniform 150 x 150 mm or a 425 x 425 mm square spot on a wedge-shaped model holder. Combined heating levels of up to 180 W/cm2 convective with either 300 W/cm2 or 100 W/cm2 are achievable. This allows the arc jet and lasers to simulate dynamic entry-heating profiles encountered during entry by the Orion crew capsule for the lunar return conditions. New computational investigations are underway to explore testing with the objective of defining ablative material failure limit. Typical arc-jet testing is performed with test article that are stagnation or wedge geometries. The existing convective heating test facility combined with test article design limits how high a combined shear, heat-flux and pressure conditions can be achieved. With the addition of laser power of 200 kW, much higher combined conditions of high heat-flux, pressure and shear is achievable on a wedge or a swept-cylinder article. Such testing possibilities will allow us to progressively increase the combined conditions and explore when an ablative TPS material may fail. The presentation provides an overview of the LEAF and present results from the on-going Orion Testing.

Venkatapathy, Ethiraj↗
NASA NTRSDate not supplied

Identification and Study of Validation Level Test Cases for Computational Modeling of Non-Charring Ablators

Computational modeling of Thermal Protection System (TPS) materials, used for aerospace applications, provides numerous advantages in preliminary selection and design of a heatshield material and shape for atmospheric entry vehicles. However, to serve as a reliable tool for prediction of material thermal and ablative behavior, the modeling approach needs to be validated against real experimental and flight data, preferably at a range of applied conditions. The validation study is typically very complex as it requires reliable measured data not only for the material thermal response and surface recession, but also well characterized environmental conditions. The validation problem becomes even more complex when the material thermal response is dictated by multi-physics effects such as solid conduction, in-depth thermal decomposition, pyrolysis gas flow and chemical reactions. The multi-physics effects complicate not only the modeling effort, but also the experimental measurement for validation of various aspects of the highly coupled problem. In this study, an attempt is made to identify suitable experimental data that could serve as a source for validation of material thermal response modeling tools. To reduce the computational complexity, this study focuses only on non-charring ablators, where the material thermal response could be modeled with a single governing equation for solid conduction and the ablation is limited only to the surface of the material. With a well characterized and publicly available experimental data being sparse, the study is limited in presenting test cases for only three materials: camphor, graphite and FiberForm® in the sequence of increased modeling complexity. Graphite is a commonly used TPS material for aerospace applications, both for leading edges of high-speed vehicles and internal insulation of solid rocket motors. FiberForm® is a porous carbon pre-form used in preparation of the well known PICA material Tran et al. [1996]. Inclusion of camphor into the list is conditioned with the relative simplicity in modeling the material thermal and chemical response and the low-enthalpy flow environment. In addition, camphor has been used as a simple test material for study of flow transition behavior by Stock and Ginoux [1973] and assessment of a heatshield shape change at flight relevant conditions by Rotondi et al. [2022]. In this work, the identified experimental data was extracted from the public literature and test cases that yet have been published. As it was found from the review, not a single test case contains an exhaustive set of data that would validate every aspect of the material physics. However, in the data collected, various aspects of the material behavior can be still validated, such as surface and in-depth temperature, amount of recession and a shape change. The identified experimental data for each case is accompanied with a characterized flow environment and simulated boundary conditions predicted by a Data-Parallel Line Relaxation (DPLR) code Wright et al. [1998]. In addition, material thermal response numerical simulations in each test case are performed with Kentucky Aerothermodynamics and Thermal Response System (KATS-MR) Zibitsker et al. [2022] providing a comparative study and a sanity check for the proposed validation data. Sample results from the performed numerical study are shown below. Figure 1 shows distribution of surface heat flux and pressure values on a hemi-cylinder model made of FiberForm® and tested in HyMETS arc-jet facility. The results are shown for the high pressure condition among the two tests. Flow simulation was performed with DPLR code on a quarter of original geometry. In the figure, the quarter shape was mirrored across zx and xy planes to show the complete distribution. Figure 2 shows the material response results for the high pressure case (7500 Pa), simulated with KATS-MR and a comparison to the experimental data for the surface temperature and shape shape. The simulation was performed on a 2-D slice, extracted in the xy plane at the middle of the sample. Figure 3 shows the material response simulation for the low pressure case (3500 Pa) and a comparison to the experimental data for surface temperature and shape change.

ablation↗
NASA NTRS2005

Performance of a Light-Weight Ablative Thermal Protection Material for the Stardust Mission Sample Return Capsule

New tests and analyses are reported that were carried out to resolve testing uncertainties in the original development and qualification of a lightweight ablative material used for the Stardust spacecraft forebody heat shield. These additional arcjet tests and analyses confirmed the ablative and thermal performance of low density Phenolic Impregnated Carbon Ablator (PICA) material used for the Stardust design. Testing was done under conditions that simulate the peak convective heating conditions (1200 W/cm2 and 0.5 atm) expected during Earth entry of the Stardust Sample Return Capsule. Test data and predictions from an ablative material response computer code for the in-depth temperatures were compared to guide iterative adjustment of material thermophysical properties used in the code so that the measured and predicted temperatures agreed. The PICA recession rates and maximum internal temperatures were satisfactorily predicted by the computer code with the revised properties. Predicted recession rates were also in acceptable agreement with measured rates for heating conditions 37% greater than the nominal peak heating rate of 1200 W/sq cm. The measured in-depth temperature response data show consistent temperature rise deviations that may be caused by an undocumented endothermic process within the PICA material that is not accurately modeled by the computer code. Predictions of the Stardust heat shield performance based on the present evaluation provide evidence that the maximum adhesive bondline temperature will be much lower than the maximum allowable of 250 C and an earlier design prediction. The re-evaluation also suggests that even with a 25 percent increase in peak heating rates, the total recession of the heat shield would be a small fraction of the as-designed thickness. These results give confidence in the Stardust heat shield design and confirm the potential of PICA material for use in new planetary probe and sample return applications.

Covington, M. A.↗
NASA NTRS2019

Bayesian Inference and the Effects of Varying Uncertainty Models in Charring Ablator Calibration and Uncertainty Quantification Problems

The Mars Science Laboratory (MSL) vehicle utilized a heat shield constructed from NASA’s Phenolic-Impregnated Carbon Ablator (PICA) material to protect the main structure from the high enthalpy environment encountered during hypersonic atmospheric entry. During the vehicle’s descent through Martian atmosphere, multiple thermocouples embedded within the heat shield captured in-depth material temperature data that allow for studies to be conducted on current material response reconstruction tools. In the present work, material temperature data obtained from thermocouples within the MISP-4 plug (MEDLI (Mars Science Laboratory Entry, Descent, and Landing Instrument) Integrated Sensor Plug) are utilized in the calibration of Theoretical Ablative Composite for Open Testing (TACOT) model parameters in conjunction with NASA’s Porous material Analysis Toolbox (PATO) through Bayesian inference where uncertainty due to parametric, modeling, and experimental sources is simultaneously quantified. Prior to the study, a sensitivity analysis is performed through computation of the robust Sobol indices in an effort to study the relationship between input space and model response and to reduce the dimensionality of the statistical inverse problem. The Bayesian inference methodology necessitates an a-priori choice to be made for the uncertainty model for which numerous possibilities are available. Across most works, however, only basic additive or multiplicative models are utilized with pre-defined magnitudes of uncertainty based on a-priori knowledge or to-be-calibrated multipliers of static covariance matrix structures. The present effort explores the effects of informed uncertainty models, ones with temporal dependence that are simultaneously calibrated through Bayesian inference, on calibrated results for parameters that make up the uncertain input space.

Sensitivity Analysis↗
NASA NTRS1974

Ablative thermal protection for space tug multipass, aerobraking entry

Analytical studies had found the employment of an aerobraking trajectory for return of a reusable Space Tug from geosynchronous missions to be feasible and practical. To establish the minimum-weight ablative dome heat shield, trajectories involving 2 and 30 perigee passes were investigated both analytically and by plasma arc testing. Silicone-base ablators with densities of 15, 30, and 50 lb/cu ft were selected for evaluation. All models withstood the multipass exposures without deleterius surface recession or char erosion. Dome heat shield weights based on optimum ablative compositions indicated that ablators are a highly efficient thermal protection system for these missions.

Strauss, E. L.↗
NASA NTRS1973

Comparison of the aerodynamic characteristics of an ablating and nonablating blunted conical body

The influence of ablation on the aerodynamic characteristics of a blunted slender cone was investigated. Plastic models were launched in free flight at ablating conditions. The results were compared with results of similar tests using metal nonablating models. Ablation was found to decrease the dynamic stability and the drag, but had little effect on static stability and lift. The plastic models appeared to experience ablation-induced roll.

Kruse, R. L.↗
NASA NTRS2017

Picosecond Pulsed Laser Ablation for the Surface Preparation of Epoxy Composites

As part of a technical challenge under the Advanced Composites Program, methods for improving pre-bond process control for aerospace composite surface treatments and inspections, in conjunction with Federal Aviation Administration guidelines, are under investigation. The overall goal is to demonstrate high fidelity, rapid and reproducible surface treatment and surface characterization methods to reduce uncertainty associated with the bonding process. The desired outcomes are reliable bonded airframe structure, and reduced timeline to certification. In this work, laser ablation was conducted using a q-switched Nd:YVO4 laser capable of nominal pulse durations of 8 picoseconds (ps). Aerospace structural carbon fiber reinforced composites with an epoxy resin matrix were laser treated, characterized, processed into bonded assemblies and mechanically tested. The characterization of ablated surfaces were conducted using scanning electron microscopy (SEM), water contact angle (WCA) goniometry, micro laser induced breakdown spectroscopy (uLIBS), and electron spin resonance (ESR). The bond performance was assessed using a double cantilever beam (DCB) test with an epoxy adhesive. The surface characteristics and bond performance obtained from picosecond ablated carbon fiber reinforced plastics (CFRPs) are presented herein.

Palmieri, Frank↗
NASA NTRS1996

Ames Research Center Shear Tests of SLA-561V Heat Shield Material for Mars-Pathfinder

This report describes the results of arc-jet testing at Ames Research Center on behalf of Jet Propulsion Laboratory (JPL) for the development of the Mars-Pathfinder heat shield. The current test series evaluated the performance of the ablating SLA-561V heat shield material under shear conditions. In addition, the effectiveness of several methods of repairing damage to the heat shield were evaluated. A total of 26 tests were performed in March 1994 in the 2 in. X 9 in. arc-heated turbulent Duct Facility, including runs to calibrate the facility to obtain the desired shear stress conditions. A total of eleven models were tested. Three different conditions of shear and heating were used. The non-ablating surface shear stresses and the corresponding, approximate, non-ablating surface heating rates were as follows: Condition 1, 170 N/m(exp 2) and 22 W/cm(exp 2); Condition 2, 240 N/m(exp 2) and 40 W/cm(exp 2); Condition 3, 390 N/m(exp 2) and 51 W/cm(exp 2). The peak shear stress encountered in flight is represented approximately by Condition 1; however, the heating rate was much less than the peak flight value. The peak heating rate that was available in the facility (at Condition 3) was about 30 percent less than the maximum value encountered during flight. Seven standard ablation models were tested, of which three models were instrumented with thermocouples to obtain in-depth temperature profiles and temperature contours. An additional four models contained a variety of repair plugs, gaps, and seams. These models were used to evaluated different repair materials and techniques, and the effect of gaps and construction seams. Mass loss and surface recession measurements were made on all models. The models were visually inspected and photographed before and after each test. The SLA-561 V performed well; even at test Condition 3, the char remained intact. Most of the resins used for repairs and gap fillers performed poorly. However, repair plugs made of SLA-561V performed well. Approximately 70 percent of the thermocouples yielded good data.

Tauber, Michael↗
NASA NTRS1977

Evaluation of three thermal protection systems in a hypersonic high-heating-rate environment induced by an elevon deflected 30 deg

Three thermal protection systems proposed for a hypersonic research airplane were subjected to high heating rates in the Langley 8 foot, high temperature structures tunnel. Metallic heat sink (Lockalloy), reusable surface insulation, and insulator-ablator materials were each tested under similar conditions. The specimens were tested for a 10 second exposure on the windward side of an elevon deflected 30 deg. The metallic heat sink panel exhibited no damage; whereas the reusable surface insulation tiles were debonded from the panel and the insulator-ablator panel eroded through its thickness, thus exposing the aluminum structure to the Mach 7 environment.

Taylor, A. H.↗