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NASA NTRS1988

Aerodynamic pressures and heating rates on surfaces between split elevons at Mach 6.6

An aerothermal study was performed in the Langley 8-Foot High Temperature Tunnel at Mach number 6.6 to define the pressures and heating rates on the surfaces between split elevons similar to those used on the Space Shuttle. Tests were performed with both laminar and turbulent boundary layers on the wing surface upstream of the elevons. The flow in the chordwise gap between the elevons was characterized by flow separation at the gap entrance and flow reattachment at a depth into the gap inversely proportional to the gap width. The gap pressure and heating rate increased significantly with decrease of elevon gap width, and the maximum gap heating rate was proportional to the maximum gap pressure. Correlation of the present results indicate that the gap heating was directly proportional to the elevon windward surface pressure and was not dependent upon whether the boundary layer on the windward elevon surface was laminar or turbulent.

Hunt, L. Roane↗

NASA NTRSDate not supplied

An Overview of the Aerothermodynamic Database for the Mars Sample Return Earth Entry Vehicle

The Mars Sample Return Earth Entry System (MSR-EES) is a capsule that is part of the Mars Sample Return mission that will return Martian soil samples to Earth in 2033. Due to the steep flight path angle and relatively large vehicle size, the MSR-EES capsule will experience the highest peak heating rate of any previous Earth entry vehicle. The aerothermal database for MSR-EES is primarily characterized by numerical CFD, DSMC, and radiation simulations. Margins are applied to the convective and radiative heating rates. Surface roughness effects and margins are also included in the database formulation. The aerothermal database can be used to extract information at any body point location, perform trade studies in trajectory space, and provide inputs for material response simulations.

Mars↗

NASA NTRS1988

Studies of aerothermal loads generated in regions of shock/shock interaction in hypersonic flow

Detailed measurements of heat transfer and pressure distribution have been made in the present study of the aerothermal characteristics of regions of two-dimensional shock/shock interaction generated by the incidence of single and multiple shocks onto the bow shock ahead of a spanwise cylinder. For transitional flows, the measurements demonstrated a large increase in the aerothermal loads with increasing Mach number that cannot be predicted by simple phenomenological models. The studies with multiple incident shocks demonstrate that the largest aerothermal loads are generated on the cylinder when the shocks coalesce before they are incident on the bow shock.

Holden, M. S.↗

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 NTRSDate not supplied

Thermal Protection System to Enable Ice Giant Aerocapture Mission for Delivering Both an Orbiter and an In Situ Probe

The Ice Giants have been identified as high priority science destinations in the last Decadal Survey [1] and could benefit from aerocapture as the primary method for orbit insertion [2]. A mass-efficient aerocapture system will enable the delivery of an orbiter along with an atmospheric probe (for in situ measurements to anchor global data collected by the orbiter) and possibly a lander at Triton [3]. Aerocapture could be executed either using low L/D rigid aeroshell with lift modulation (LMA) [4] or using deployable aeroshell using drag modulation (DMA) [3]. Nearly two decades ago, a NASA-funded team performed Neptune-Triton aerocapture studies with a mid-L/D lifting configuration [5] for achieving orbit using LMA. This study showed aerocapture challenges. Due to very high peak entry conditions combined with very high heat-load, a suite of TPS materials was required and this suite was deemed problematic from a qualification perspective, due test facility limitations. In the past 20 years, progress made in GN&C for lift-guided entry missions such as MSL, Orion EFT1, Mars 2020 and the upcoming Artemis missions, and the expertise in blunt body aerodynamics at large scale (~ 5m) has led the EDL community to conclude that aerocapture is a “go do” engineering activity and most technologies are in hand to propose missions with aerocapture [6] [7]. Aerocapture using DMA, currently in development, is an option for Ice Giant Missions. While DMA is simpler in some sense, due to ballistic entry and no need for lift-guided maneuvering, it has challenges and it’s maturity is lower. LMA and DMA both require one or more ablative Thermal Protection System (TPS) materials for the rigid aeroshell element. The ablative TPS needs to be robust and mass efficient due to the high heat loads and size of the rigid aeroshell. Currently, there are capable ablative thermal protection materials, e.g., Heatshield for Extreme Entry Environments Technology (HEEET), 3-D woven Mid-Density Carbon- Phenolic (3MDCP), and PICA (Phenolic-Impregnated Carbon Ablator) that are mature, i.e., at TRL 6 or higher. NASA also invested in Conformal PICA that was matured to TRL 5. Our goal is to evaluate the applicability of high TRL TPS and consider other design options. We first establish bounding aerocapture trajectories for a wide range of arrival conditions and the associated aerothermal environment. Based on the environments, we then determine the predicted TPS mass for the aeroshell [4]. In this presentation, we will outline the process by which we establish bounding aerocapture trajectories for hyperbolic excess velocities ranging from 27 km/s to 35 km/s, which are shown to be a range of velocities that can reduce the trip time from ~14 years to 8 years. The above velocity range translates to ~12 km/s to ~24 km/s arrival velocities at the planetary entry interface [2]. The velocity reduction required to achieve orbit ranges between ~2.5 km/s to 9.5 km/s for both Neptune and Triton. Propulsive insertion alone, due to the amount of fuel required to achieve the required velocity reduction, limits the science returned [2]. We establish the bounding aerocapture trajectories for a low L/D (~ 0.4) configuration for three different ballistic coefficients. The ballistic coefficient range is determined from three different aeroshell diameters of 3m, 4m and 5m and with an entry system mass of 2200 kg. With the above range of design parameters, we then determine conservative/bounding estimates of aerothermal environments by using a combination of CFD simulations and stagnation point heating estimates [7]. This engineering approach allows us to first assess the TPS need vs. TPS capability and determine the applicability of existing TPS. Once an applicable suite of TPS is determined, the TPS thickness and mass are computed. We show that the TPS mass fraction can be as low as 5% to as high as 20%, depending on total trip time reduction and other design parameters for a range of TPS. This is a large range for TPS mass fraction. We show PICA and HEEET can indeed enable aerocapture missions, but the missions incur a mass penalty. TPS mass savings, can be further reduced with the use of conformal PICA. Advancing the development of Conformal PICA to make it robust across the entire aerothermal environment (peak heat-flux, pressure and shear) range will result in TPS mass fractions of < 10% for Ice Giant aerocapture missions such as the Neptune-Triton mission. Aerocapture allows for not only shortening the trip time but enables larger mass to be placed in orbit. Furthermore, probes deployed from orbit will benefit in reduced entry environments allowing for a lower risk TPS implementation as compared to mission designs where the probe is released prior to orbit insertion. One of the challenges for the Ice Giant community is to ensure mission designs that maximize science and allow flexibility in the placement of the entry probe. The traditional approach to release the probe ahead of the orbiter may not optimize returned science. In this presentation, we will make the case for mature TPS such as HEEET and PICA. While these materials can enable aerocapture missions, completing the development of conformal PICA and extending Conformal PICA to be more robust, will have significant impact to TPS mass efficiency and significantly enhance science return for future Gas- and Ice-Giant missions.

E Venkatapathy↗

NASA NTRSDate not supplied

MEDLI2: MISP Measured Aftbody Aerothermal Environments

The Mars Entry, Descent, and Landing Instrumentation 2 (MEDLI2) sensor suite on the Mars 2020 mission included two total heat flux sensors and one radiometer on the backshell to directly measure the aftbody aerothermal environments during entry into the Martian atmosphere. All three sensors successfully returned aftbody entry heating measurements. Comparisons between the total heat flux sensor measurements and DPLR/NEQAIR predictions show excellent agreement and provide confidence in the models. The radiometer measured significant radiative heating but compared to the model predictions the signal was attenuated by 50% at the end of the entry heat pulse. The loss of signal is attributed to blockage by thermal protection system (TPS) ablation product deposits on the radiometer window. Ground-based testing in the NASA Ames arc jet facilities was conducted to understand the impact of ablation product deposits on the measured radiometer signal. A discussion of the test results, how flight-like the test conditions were, and future work to further characterize the effect of TPS ablation product deposits on the radiometer performance are presented. In addition to measuring the entry heat pulse all three sensors were sensitive enough to measure solar radiation during cruise, the radiometer measured solar flux during the entry heat pulse, and the leeside total heat flux sensor picked up the descent reaction control system firings.

Ruth A Miller↗

NASA NTRSDate not supplied

Aerothermal Analysis of the Dragonfly Titan Entry

The Dragonfly mission will send a rotorcraft lander to the surface of Saturn’s moon Titan as part of the New-Frontiers program. This will be the first spacecraft to land on Titan since the Huygens probe’s descent in January of 2005 and only the second spacecraft to enter Titan’s atmosphere. The Dragonfly entry capsule is significantly larger than the Huygens probe and will experience higher aerothermal environments. This poster will provide an overview of the aerothermodynamic models used in the Dragonfly aeroshell design process. Titan provides a unique entry environment that has several fundamental differences from the environments at the more common entry destinations of Earth and Mars. The lack of atmospheric oxygen significantly reduces heatshield recession (expected to be negligible), which simplifies material response analysis but also reduces the efficiency of the thermal protection system. The atmos-phere is composed of mostly nitrogen and trace amounts of methane. During hypersonic entry this methane dissociates and leads to the formation of the molecule CN, which is known to radiate strongly in the shock layer. Current Dragonfly heating predictions estimate that radiation contributes about 50% of the total heat flux along the forebody and up to 90% on the aftbody, making radiation a key element of aerothermal analysis. To properly address the importance of radiation, a unique radiative-heating correlation was developed that incorporates normal-shock equilibrium chemistry predictions based on work from the Mars 2020 program. These new heating correlations agree well with Computational Fluid Dynamics (CFD) predictions and enable large-scale trajectory analyses by providing rapid heating predictions along candidate trajectories. Dragonfly aerothermal environments are generated with the Data Parallel Line Relaxation (DPLR) finite-volume Navier-Stokes solver alongside the Nonequilibrium Radiative Transport and Spectra (NEQAIR) radiation transport code. DPLR produces shock-aligned flowfields that incorporate the effects of both chemical and thermal nonequilibrium while NEQAIR solves the radiation transport equations along lines-of-sight through the flowfield solutions to predict the radiative heating on the aeroshell. Titan’s atmosphere produces complex thermal and chemical nonequilibria and so classical radiation approximations that extrapolate from a single line-of-sight, such as the Tangent-Slab method, were found to overpredict peak radiative heat fluxes by 10-20%. Therefore, all radiative heating is directly calculated using 3-D transport for both the forebody and aftbody to reduce unnecessary conservatism. A 21-species finite-rate chemistry model, including electrons and ionized species, is used in the CFD to ensure accurate vehicle heating predictions (the level of ionization is particularly for accurate radiative flux predictions). This poster will cover: 1) The models and assumptions used to simulate entry into Titan’s atmosphere, 2) Dragonfly aerothermal engineering correlations alongside statistical heating values, and 3) Driving aerothermal considerations for a Titan entry such as CN formation and radiation-flowfield coupling.

EDL↗

NASA NTRS1989

The critical role of aerodynamic heating effects in the design of hypersonic vehicles

Hypersonic vehicles operate in a hostile aerothermal environment, which has a significant impact on their aerothermostructural performance. Significant coupling occurs between the aerodynamic flow field, structural heat transfer, and structural response, creating a multidisciplinary interaction. The critical role of aerodynamic heating effects in the design of hypersonic vehicles is identified with an example of high localized heating on an engine-cowl leading edge. Recent advances is integrated fluid-thermal-structural finite-element analyses are presented.

Wieting, Allan R.↗

NASA NTRS1980

Aerothermal analysis of a wing-elevon cove with variable leakage

A mathematical model of the heating associated with leakage within the space shuttle orbiter wing elevon cove was used to analyze the aerothermal response of the structure. The analysis was applied to wind tunnel results and to shuttle entry conditions. A parametric study described the mechanism by which the energy of the ingested mass is distributed as a function of the Reynolds number, wall conductivity, surface emissivity, and cove height and length. The rate at which energy was transferred into the cove interior was primarily determined by the combined effects of the convection, wall capacitance, and internal radiation terms. Correlation with wind tunnel results indicated that the cold wall convective heating rates, wall temperature, and gas temperature of the cove were predicted by the analytical model for short exposure times. Predicted transient thermal response of the elevon cove subjected to shuttle entry conditions indicated that the allowable leak area at the cove seal was 20 percent less than that previously indicated by experiment.

Hunt, R. L.↗

NASA NTRS2015

Development of an Ablative 3D Quartz / Cyanate Ester Composite for the Orion Spacecraft Compression Pad

With the successful flight test of the Orion Multipurpose Crew Vehicle last December, NASA is well on its way to sending humans into deep space with the ultimate goal of putting astronauts on Mars in the 2030s. Orion will receive some upgrades for its next launch in 2018 including a newly developed 3D quartz / cyanate ester composite material for the compression pad. Multiple pad locations in the heat shield serve as a part of the mechanism for holding the Crew and Service Modules together during most mission phases prior to separation followed by Earth re-entry of the Crew Module. Thus the compression pad must survive structural and aerothermal loads, and protect the adjascent structure and heat shield materials from over-heating.This paper describes the approach used for developing the new 3D composite, including continuous 3D weaving on an automated loom followed by resin transfer molding. Mechanical, thermal, arc jet ,and stress relaxation testing of the 3D composite are also described.

Feldman, Jay D.↗

NASA NTRS2023

Application of Thermal Loads to a Numerical Model

A detailed aerothermal model requires the application of the heat flux profile over all exposed aerodynamic surfaces. These loads are created using both engineering methods (e.g., FORTRAN codes implementing correlations) and CFD simulations (e.g., solutions to Navier-Stokes equations). The goal is to define the spatial and temporal dependency of the heat flux upon the model.

cfd↗

NASA NTRS2019

Simulation Schiaparelli's Entry and Comparison to Aerothermal Flight Data

The European Space Agency recently flew an entry, descent, and landing demonstrator module called Schiaparelli that entered the atmosphere of Mars on the 19th of October, 2016. The instrumentation suite included heatshield and backshell pressure transducers and thermocouples (known as AMELIA - Atmospheric Mars Entry and Landing Investigations and Analysis) and backshell radiation and direct heat flux-sensing sensors (known as COMARS (Combined Aerothermal and Radiometer Sensors Instrument Package) and ICOTOM (narrow band radiometers)). Due to the failed landing of Schiaparelli, only a subset of the flight data was transmitted before and after plasma black-out. The goal of this paper is to present comparisons of the flight data with calculations from NASA simulation tools, DPLR (Data Parallel Line Relaxation) / NEQAIR (NonEQuilibrium AIr Radiation) and LAURA (Langley Aerothermodynamic Upwind Relaxation Algorithm) / HARA (High-temperature Aerothermodynamic RAdiation ). DPLR and LAURA are used to calculate the flowfield around the vehicle and surface properties, such as pressure and convective heating. The flowfield data are passed to NEQAIR and HARA to calculate the radiative heat flux. Comparisons will be made to the COMARS total heat flux, radiative heat flux and pressure measurements. Results will also be shown against the reconstructed heat flux which was calculated from an inverse analysis of the AMELIA thermocouple data performed by Astrium. Preliminary calculations are presented in this abstract.

Brandis, A. M.↗

NASA NTRS1993

Aerodynamic heating environment definition/thermal protection system selection for the HL-20

Definition of the aerothermal environment is critical to any vehicle such as the HL-20 Personnel Launch System that operates within the hypersonic flight regime. Selection of an appropriate thermal protection system design is highly dependent on the accuracy of the heating-environment prediction. It is demonstrated that the entry environment determines the thermal protection system design for this vehicle. The methods used to predict the thermal environment for the HL-20 Personnel Launch System vehicle are described. Comparisons of the engineering solutions with computational fluid dynamic predictions, as well as wind-tunnel test results, show good agreement. The aeroheating predictions over several critical regions of the vehicle, including the stagnation areas of the nose and leading edges, windward centerline and wing surfaces, and leeward surfaces, are discussed. Results of predictions based on the engineering methods found within the MINIVER aerodynamic heating code are used in conjunction with the results of the extensive wind-tunnel tests on this configuration to define a flight thermal environment. Finally, the selection of the thermal protection system based on these predictions and current technology is described.

Wurster, K. E.↗

NASA NTRS2002

Prediction of Drag Reduction in Supersonic and Hypersonic Flows with Counterflow Jets

Computational fluid dynamics solutions of the flowfield of a truncated cone-cylinder with and without counterflow jets have been obtained for the short penetration mode (SPM) and long penetration mode (LPM) of the freestream-counterflow jet interaction flowfield. For the case without the counterflow jet, the comparison of the normalized surface pressures showed very good agreement with experimental data. For the case with the SPM jet, the predicted surface pressures did not compare as well with the experimental data upstream of the expansion corner, while aft of the expansion corner, the comparison of the solution and the data is seen to give much better agreement. The difference in the prediction and the data could be due to the transient character of the jet penetration modes, possible effects of the plasma physics that are not accounted for here, or even the less likely effect of flow turbulence, etc. For the LPM jet computations, one-dimensional isentropic relations were used to derived the jet exit conditions in order to obtain the LPM solutions. The solution for the jet exit Mach number of 3 shows a jet penetration several times longer than that of the SPM, and therefore much weaker bow shock, with an attendant reduction in wave drag. The LPM jet is, in essence, seen to be a "pencil" of fluid, with much higher dynamic pressure, embedded in the oncoming supersonic or hypersonic freestream. The methodology for determining the conditions for the LPM jet could enable a practical approach for the design and application of counterflow LPM jets for the reduction of wave drag and heat flux, thus significantly enhancing the aerodynamic characteristics and aerothermal performance of supersonic and hypersonic vehicles. The solutions show that the qualitative flow structure is very well captured. The obtained results, therefore, suggest that counterflowing jets are viable candidate technology concepts that can be employed to give significant reductions in wave drag, heat flux, and other attendant aerodynamic benefits.

Daso, Endwell O.↗

NASA NTRSDate not supplied

Aeroheating Testing of the Mars Sample Return Earth Entry System with Surface Roughness

The Mars Sample Return Earth Entry System is a mission concept which would be the first NASA entry vehicle to utilize a woven thermal protection system as well as a 52.5 degree sphere-cone forebody geometry. Due to its novel design, historic experimental data sets were insufficient to validate the models used to characterize the expected aerothermal environment. A wind tunnel test campaign was funded by the Mars Sample Return Earth Entry System project in the NASA Langley 20-Inch Mach 6 Air Tunnel in order to obtain validation data. The December 2023 test entry of this campaign sought to obtain thermographic data to capture the impact of supersonic flow near woven surface roughness elements on convective heating augmentation, which was the largest remaining uncertainty in aerothermal design of the Earth Entry System. Data obtained were in family with prior results obtained on identical woven patterns without supersonic flow present at roughness elements, and it was found that this presence of supersonic flow did not have a noticeable effect on surface convective heating augmentation. Data were directly leveraged to support the NASA Mars Sample Return flight program and this data set is valuable for validating computational solutions on roughness-resolved grids.

Mars Sample Return↗

NASA NTRSDate not supplied

Aeroheating Testing of the Mars Sample Return Earth Entry System with Surface Roughness

Mars Sample Return↗

NASA NTRS1977

Experimental performance of an ablative material as an external insulator for a hypersonic research aircraft

An ablative material composed of silica-filled elastomeric silicone was tested to evaluate its thermal and structural performance as an external insulator, or heat shield, for a hypersonic research aircraft. The material was also tested to determine whether it would form a durable char layer when initially heated and thereafter function primarily as an insulator with little further pyrolysis or char removal. Aerothermal tests were representative of nominal Mach 6 cruise conditions of the aircraft, and additional tests were representative of Mach 8 cruise and interference heating conditions. Radiant heating tests were used to simulate the complete nominal Mach 6 surface-temperature history. The silica char that formed during aerothermal tests was not durable. The char experienced a general and preferential surface recession, with the primary mechanism for char removal being erosion. Tests revealed that radiant heating is not a valid technique for simulating aerodynamic heating of the material.

Puster, R. L.↗

NASA NTRSDate not supplied

Pterodactyl: Thermal Protection System Design Methodology for a Flap Control System

As interest in non-traditional entry vehicles continues to grow, the need for a Thermal Protection System (TPS) analysis approach that can account for entry solutions with changing geometry and complicated flow dynamics becomes invaluable. The NASA Space Technology Mission Directorate (STMD) Pterodactyl project aims to accomplish this through examination of a flap controlled Adaptable, Deployable Entry Placement Technology (ADEPT)-style Deployable Entry Vehicle (DEV). This paper details an improved methodology for modeling the aerothermodynamic environment and initial TPS design for a flap control system integrated with a symmetric DEV. Improvements include i) the addition of an anchoring process that uses an increased fidelity aerodynamic solution to anchor the aerothermal environment predictions and ii) increased surface resolution, for the 1D heat transfer analysis, to isolate the hottest area on the flap that will require the thickest TPS. It was found that the anchoring process provided an improved aerothermal environment prediction. Additionally, this analysis demonstrated that there is a need for increased surface resolution in the 1D thermal analysis since the predicted location of the hottest point was significantly different than the location identified using very coarse surface resolution.

Zane B Hays↗