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Implementing the 3-D woven Mid-Density Carbon Phenolic (3MDCP) Heat Shield for the Mars Sample Return (MSR) Earth Entry Vehicle (EEV)

he Mars Sample Return (MSR)Program will return Martian soil samples to Earth in the early 2030s. Since the biological content of these samples is unknown, and potentially upsetting to Earth’s biosphere, the Earth Entry Vehicle (EEV) is required to be the most reliable entry probe ever devised. Entering Earth’s atmosphere at ~12 km/s, after up to a 6-day in-space free flight phase, the EEV must tolerate the cis-lunar Micro-Meteoroid environment, the near-Earth Orbital debris environment, and then entry heating of over 3,000 W/cm2 and pressures of250 kPa before ballistically impacting Earth’s surface at nearly 45 m/s. To reliably accomplish such a mission, NASA Ames is implementing the 3-D woven Mid-Density Carbon Phenolic (3MDCP) Heat Shield, derived from the prior Heatshield for Extreme Entry Environments(HEEET) material system [1]. 3MDCP development accomplishments to date, along with the future efforts to deliver the flight hardware are presented, along with a discussion of the manufacturing risks and accompanying mitigations achieved.

J C Vander Kam

3D Woven Mid-Density Carbon Phenolic (3MDCP) Full-Scale Heatshield Development for Mars Sample Return (MSR) Earth Entry System (EES)

The Mars Sample Return (MSR) mission will be returning samples of Martian soil to Earth. The samples will be returned in the Earth Entry System (EES). The EES capsule is protected by a new thermal protection system; the 3-Dimensionally Woven, Mid-Density, Carbon Phenolic (3MDCP) material which is derived from the Heatshield for Extreme Entry Environment Technology (HEEET). The baseline 3MDCP design is a single piece thermal protection system that avoids the manufacturing and certification challenges associated with a tiled configuration. A 3MDCP heatshield begins as a flat woven preform that is formed to the final heatshield shape and then infused with phenolic resin. A NASA Ames lead team, in collaboration with Spirit Textiles (formerly TEAM Inc.), Fiber Materials Inc. (FMI, a Spirit AeroSystems Company), and Kratos SRE, has been developing and demonstrating the processes to fabricate the 3MDCP heatshield and characterize the resulting properties. The process of forming the flat woven preform into the final heatshield shape, a sphere-cone geometry with a 52.5° cone angle, involves local but substantial movement of the yarns in the weave. This results in continuous fibers across the single piece heatshield, albeit with property variations between different regions of the heatshield. This presentation will provide a high-level status of 3MDCP development for the MSR EES heatshield. This will include an overview of the manufacturing processes with an emphasis on the impact of forming on fiber orientation, material properties, and performance. Results comparing preliminary formed and flat materials will be shown. Additionally, the presentation will layout the broader plan for property testing and tie-in to aerothermal performance.

Peter Edward Marshall

FE Simulation of SMA Seal for Mars Sample Return

Several NASA rovers and landers have been on Mars and performed successful in-situ exploration. Returning Martian samples to Earth for extensive analysis is of great interest to the planetary science community. Current Mars sample return architecture would require leaving the acquired samples on Mars for years before being retrieved by subsequent mission. Each sample would be sealed securely to keep its integrity. A reliable seal technique that does not affect the integrity of the samples and uses a simple low-mass tool is required. The shape memory alloy (SMA) seal technique is a promising candidate. A study of the thermal performances of several primary designs of a SMA seal for sample tubes by finite element (FE) simulation are presented in this paper. The results show sealing the sample tube by SMA plugs and controlling the sample temperature below the allowed temperature level are feasible.

seal

Mars Sample Return Using Commercial Capabilities: Propulsive Entry, Descent and Landing

Mars Sample Return (MSR) is the highest priority science mission for the next decade as recommended by the recent Decadal Survey of Planetary Science. The objective of the study was to determine whether emerging commercial capabilities can be integrated into to such a mission. The premise of the study is that commercial capabilities can be more efficient than previously described systems, and by using fewer systems and fewer or less extensive launches, overall mission cost can be reduced. This presentation describes an EDL technique using planned upgrades to the Dragon capsule to perform a Supersonic Retropulsion Entry - Red Dragon concept. Landed Payload capability meets mission requirements for a MSR Architecture that reduces complexity.

Entry

Thermal Protection for Mars Sample Return Earth Entry Vehicle: A Grand Challenge for Design Methodology and Reliability Verification

Mars Sample Return is our Grand Challenge for the coming decade. TPS (Thermal Protection System) nominal performance is not the key challenge. The main difficulty for designers is the need to verify unprecedented reliability for the entry system: current guidelines for prevention of backward contamination require that the probability of spores larger than 1 micron diameter escaping into the Earth environment be lower than 1 million for the entire system, and the allocation to TPS would be more stringent than that. For reference, the reliability allocation for Orion TPS is closer to 11000, and the demonstrated reliability for previous human Earth return systems was closer to 1100. Improving reliability by more than 3 orders of magnitude is a grand challenge indeed. The TPS community must embrace the possibility of new architectures that are focused on reliability above thermal performance and mass efficiency. MSR (Mars Sample Return) EEV (Earth Entry Vehicle) will be hit with MMOD (Micrometeoroid and Orbital Debris) prior to reentry. A chute-less aero-shell design which allows for self-righting shape was baselined in prior MSR studies, with the assumption that a passive system will maximize EEV robustness. Hence the aero-shell along with the TPS has to take ground impact and not break apart. System verification will require testing to establish ablative performance and thermal failure but also testing of damage from MMOD, and structural performance at ground impact. Mission requirements will demand analysis, testing and verification that are focused on establishing reliability of the design. In this proposed talk, we will focus on the grand challenge of MSR EEV TPS and the need for innovative approaches to address challenges in modeling, testing, manufacturing and verification.

Design and Verification for Reliability

Mars Sample Return and The Capture, Containment, and Return System New Design and Path To 2027 Launch

The Mars Sample Return (MSR) campaign is one of the most ambitious and complex exoplanet scientific exploration missions currently underway. With the participation of NASA, ESA, and a large number of industry partners, MSR aims to bring back Martian rock and atmosphere samples with the goal of answering key questions about Mars’ geological, climatological, and (potentially) biological evolution. To accomplish this ambitious goal, the campaign relies on three distinct flight elements and a ground element. The Earth Return Orbiter (ERO) mission that would host the Capture, Containment, and Return System (CCRS) is the last element of the trio. The mission would capture the orbiting sample in low Mars orbit (launched into orbit by another mission), contain it and return it to Earth, landing it at the Utah Test and Training Range (UTTR). The CCRS continues its development. Since its early architecture, several changes were adopted by the project in order to improve overall payload efficiency and reduce mass. CCRS is currently on track to achieve the next milestone, Critical Design Review, expected in late 2024. This paper will discuss the CCRS design, how the current architecture contributes to an improved mission baseline, and the next critical steps of the mission towards its launch.

Mars mission

A Mars Sample Return Sample Handling System

We present a sample handling system, a subsystem of the proposed Dragon landed Mars Sample Return (MSR) mission [1], that can return to Earth orbit a significant mass of frozen Mars samples potentially consisting of: rock cores, subsurface drilled rock and ice cuttings, pebble sized rocks, and soil scoops. The sample collection, storage, retrieval and packaging assumptions and concepts in this study are applicable for the NASA's MPPG MSR mission architecture options [2]. Our study assumes a predecessor rover mission collects samples for return to Earth to address questions on: past life, climate change, water history, age dating, understanding Mars interior evolution [3], and, human safety and in-situ resource utilization. Hence the rover will have "integrated priorities for rock sampling" [3] that cover collection of subaqueous or hydrothermal sediments, low-temperature fluidaltered rocks, unaltered igneous rocks, regolith and atmosphere samples. Samples could include: drilled rock cores, alluvial and fluvial deposits, subsurface ice and soils, clays, sulfates, salts including perchlorates, aeolian deposits, and concretions. Thus samples will have a broad range of bulk densities, and require for Earth based analysis where practical: in-situ characterization, management of degradation such as perchlorate deliquescence and volatile release, and contamination management. We propose to adopt a sample container with a set of cups each with a sample from a specific location. We considered two sample cups sizes: (1) a small cup sized for samples matching those submitted to in-situ characterization instruments, and, (2) a larger cup for 100 mm rock cores [4] and pebble sized rocks, thus providing diverse samples and optimizing the MSR sample mass payload fraction for a given payload volume. We minimize sample degradation by keeping them frozen in the MSR payload sample canister using Peltier chip cooling. The cups are sealed by interference fitted heat activated memory alloy caps [5] if the heating does not affect the sample, or by crimping caps similar to bottle capping. We prefer cap sealing surfaces be external to the cup rim to prevent sample dust inside the cups interfering with sealing, or, contamination of the sample by Teflon seal elements (if adopted). Finally the sample collection rover, or a Fetch rover, selects cups with best choice samples and loads them into a sample tray, before delivering it to the Earth Return Vehicle (ERV) in the MSR Dragon capsule as described in [1] (Fig 1). This ensures best use of the MSR payload mass allowance. A 3 meter long jointed robot arm is extended from the Dragon capsule's crew hatch, retrieves the sample tray and inserts it into the sample canister payload located on the ERV stage. The robot arm has capacity to obtain grab samples in the event of a rover failure. The sample canister has a robot arm capture casting to enable capture by crewed or robot spacecraft when it returns to Earth orbit

Wilson, David

Mars sample return: Recommended sites

Site selection priorities for a Mars sample return are constrained by the risks due to terrain that affect the successful descent and mobility of the sampling vehicle. At this time, evaluations of terrain roughness can be made only in a very general way. For this reason, the two candidate sites discussed are provisionally recommended primarily on the basis of their scientific value; however, no adverse surface conditions are discernable at these locations at the resolution of Viking images. The rationale is given for the selection of the sites.

Scott, D. H.

Mars sample return mission: Two alternate scenarios

Two scenarios for accomplishing a Mars Sample Return mission are presented. Mission A is a low-cost, low-mass scenario, while Mission B is a high-technology, high-science alternative. Mission A begins with the launch of one Titan 4 rocket with a Centaur G' upper stage. The Centaur performs the trans-Mars injection burn and is then released. The payload consists of two lander packages and the orbital transfer vehicle, which is responsible for supporting the landers during launch and interplanetary cruise. Near Mars, the landers separate - one bound for a polar site and the other for an equatorial site. After descending to the surface, the landers deploy small, local rovers to collect samples. The rovers return these samples to the landers for loading on the direct return rockets, which return the samples directly to the Earth's surface. Mission B starts with four Titan 4 launches, used to place the components of the planetary transfer vehicle (PTV) into orbit. The fourth launch payload is able to move to assemble the entire vehicle by simple docking routines. Once complete, the PTV begins a low-thrust trajectory out from low Earth orbit, through interplanetary space, and into low Mars orbit. It deploys a communications satellite into a one half sol orbit and then releases the lander pad cage at 500 km altitude. The lander package contains the lander, the Mars ascent vehicle (MAV), two lighter-than-air rovers (called Aereons), and one conventional land rover. The entire package is contained within a biconic aeroshell. After release from the PTV the lander package descends to the surface, where all three rovers are released to collect samples and map the terrain. The Aereons attempt to circumnavigate Mars and collect samples from a wide variety of sites, while the land rover examines a local area more thoroughly. The Aereons are equipped with small sample return rockets that can return their samples to the lander in the event that an Aereon is incapable of returning to the lander itself. Once all samples have been collected they are loaded onto the MAV and launched into orbit. The PTV then collects the samples and returns them to Earth orbit for recovery.

Source record

Project Hyreus: Mars sample return mission utilizing in situ propellant production

Project Hyreus is an unmanned Mars sample return mission that utilizes propellants manufactured in situ from the Martian atmosphere for the return voyage. A key goal of the mission is to demonstrate the considerable benefits of using indigenous resources and to test the viability of this approach as a precursor to manned Mars missions. The techniques, materials, and equipment used in Project Hyreus represent those that are currently available or that could be developed and readied in time for the proposed launch date in 2003. Project Hyreus includes such features as a Mars-orbiting satellite equipped with ground-penetrating radar, a large rover capable of sample gathering and detailed surface investigations, and a planetary science array to perform on-site research before samples are returned to Earth. Project Hyreus calls for the Mars Landing Vehicle to land in the Mangala Valles region of Mars, where it will remain for approximately 1.5 years. Methane and oxygen propellant for the Earth return voyage will be produced using carbon dioxide from the Martian atmosphere and a small supply of hydrogen brought from Earth. This process is key to returning a large Martian sample to Earth with a single Earth launch.

Abrego, Anita

Project Hyreus: Mars Sample Return Mission Utilizing in Situ Propellant Production

Project Hyreus is an unmanned Mars sample return mission that utilizes propellants manufactured in situ from the Martian atmosphere for the return voyage. A key goal of the mission is to demonstrate the considerable benefits of using indigenous resources and to test the viability of this approach as a precursor to manned Mars missions. The techniques, materials, and equipment used in Project Hyreus represent those that are currently available or that could be developed and readied in time for the proposed launch date in 2003. Project Hyreus includes such features as a Mars-orbiting satellite equipped with ground-penetrating radar, a large rover capable of sample gathering and detailed surface investigations, and a planetary science array to perform on-site research before samples are returned to Earth. Project Hyreus calls for the Mars Landing Vehicle to land in the Mangala Valles region of Mars, where it will remain for approximately 1.5 years. Methane and oxygen propellant for the Earth return voyage will be produced using carbon dioxide from the Martian atmosphere and a small supply of hydrogen brought from Earth. This process is key to returning a large Martian sample to Earth with a single Earth launch.

Bruckner, A. P.

Mars Sample Return: Risk Management & Sample Safety Assessment

Returning samples from Mars has long been a major planetary science objective due to the high scientific value and transformative potential of the resulting data. An exciting dimension of this objective is the potential for the detection of ancient microbiological life, and the possibility of improving our understanding of the evolution of habitable environments on Mars and the development of life on Earth. To ensure that returned samples meet stringent planetary protection requirements and do not expose Earth to potential biohazards, the joint NASA/ESA Sample Receiving Project (SRP) assembled the Sample Safety Assessment Protocol Tiger Team (SSAP-TT). Members were recruited with the specific goal of creating a multi-disciplinary and internationally distributed team of experts in their respective fields across the federal government, academia, and private industry. This team was chartered with reassessing previous sample safety assessment strategies, defining what constitutes a biological hazard, developing a protocol to test for potential biohazards, and establishing a statistical framework to determine if samples are “safe” for release. The team developed a three-step protocol, supported by a Bayesian statistical framework, to assess whether returned samples contain potential biohazards that could present a risk to Earth’s biosphere. Initial conclusions indicated that an effective and comprehensive safety assessment protocol is feasible using modern techniques and does not require an excessive amount of sample consumption or traditional microbiological detection methodology. Herein, we will present an overview of the MSR SRP, the proposed safety assessment protocol, and how aspects of this novel approach can be applied to biological assessment in healthcare product manufacturing practices.

Alvin L Smith

Mars Sample Return: The Value of Depth Profiles

Sample return from Mars offers the promise of data from Martian materials that have previously only been available from meteorites. Return of carefully selected samples may yield more information about the history of water and possible habitability through Martian history. Here we propose that samples collected from Mars should include depth profiles of material across the interface between weathered material on the surface of Mars into unweathered parent rock material. Such profiles have the potential to yield chemical kinetic data that can be used to estimate the duration of water and information about potential habitats on Mars.

Hausrath, E. M.

Seeking Signs of Life on Mars: the Importance of Sedimentary Suites as Part of a Mars Sample Return Campaign

Seeking the signs of life on Mars is often considered the "first among equal" objectives for any potential Mars Sample Return (MSR) campaign. Among the geological settings considered to have the greatest potential for recording evidence of ancient life or its pre-biotic chemistry on Mars are lacustrine (and marine, if ever present) sedimentary depositional environments. This potential, and the possibility of returning samples that could meaningfully address this objective, have been greatly enhanced by investigations of an ancient redox stratified lake system in Gale crater by the Curiosity rover.

Mangold, N.

Heatshield for Extreme Entry Environment Technology (HEEET) Enabling the Mars Sample Return (MSR) Mission

NASA’s Science Mission Directorate and the European Space Agency are pursing a Mars Sample Return (MSR) mission to collect and return samples of Martian rocks, soils and atmosphere from the surface of Mars to Earth. The goals of this campaign are deepen understanding of whether life ever existed on Mars and, in turn, better understand the origins of life on Earth. The heatshield for the EEV will use a 3D Mid-density Carbon Phenolic (3MDCP) system that is derived from the Insulating Layer of Heatshield for Extreme Entry Environments Technology (HEEET) family of TPS materials.

HEEET

Arc Jet Testing of Carbon Phenolic for Mars Sample Return and Future NASA Missions

The objective of the Mars Sample Return (MSR) Mission is to return a sample of MArtian soil to Earth. The Earth Entry Vehicle (EEV) brings te samples through the atmosphere to the ground.The program aims to: Model aerothermal environment during EEV flight; On the basis of results, select potential TPS materials for EEV forebody; Fabricate TPS materials; Test the materials in the arc jet environment representative of predicted flight environment;Evaluate material performance; Compare results of modeling predictions with test results.

Laub, Bernard