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At least 127 records · Page 7

Fracture in Phenolic Impregnated Carbon Ablator

The thermal protection materials used for spacecraft heat shields are subjected to various thermal-mechanical loads during an atmospheric reentry which can threaten the structural integrity of the system. This paper discusses the development of a novel technique to understand the failure mechanisms inside the thermal protection material, Phenolic Impregnated Carbon Ablator (PICA). PICA has successfully flown on the Stardust spacecraft and was the TPS material chosen for the Mars Science Laboratory (MSL), that will fly in 2011. Although PICA has good thermal properties, structurally, it is a weak material. To thoroughly understand failure in PICA, experiments were performed using FiberForm(Registered TradeMark) (precursor of PICA), virgin and furnace-charred PICA. Several small samples were tested inside an electron microscope to investigate the failure mechanisms. Micrographs were obtained before and after the failure in order to study crack initiation and growth. Videos were obtained to capture failure mechanisms in real time. Stress-strain data was obtained simultaneously for all the samples with the help of a data acquisition system, integrated to the mechanical stages. It was found that cracks initiated and grew in the FiberForm when a critical stress limit was reached such that the carbon fibers separated from the binder. However, both for virgin and charred PICA, crack initiation and growth occurred in the matrix (phenolic) phase. Both virgin and charred PICA showed greater strength values compared to FiberForm coupons, confirming that the presence of the porous matrix helps in absorbing the fracture energy.

Agrawal, Parul↗

Fracture in Phenolic Impregnated Carbon Ablator

The thermal protection materials used for spacecraft heat shields are subjected to various thermal-mechanical loads during an atmospheric entry which can threaten the structural integrity of the system. This paper discusses the development of a novel technique to understand the failure mechanisms inside thermal protection materials. The focus of research is Phenolic Impregnated Carbon Ablator (PICA). It has successfully flown on the Stardust spacecraft and is the TPS material chosen for the Mars Science Laboratory (MSL) and Dragon spacecraft. Although PICA has good thermal properties, structurally, it is a weak material. In order to thoroughly understand failure in PICA, fracture tests were performed on FiberForm* (precursor of PICA), virgin and charred PICA materials. Several samples of these materials were tested to investigate failure mechanisms at a microstructural scale. Stress-strain data were obtained simultaneously to estimate the fracture toughness. It was found that cracks initiated and grew in the FiberForm when a critical stress limit was reached such that the carbon fibers separated from the binder. However, both for virgin and charred PICA, crack initiation and growth occurred in the matrix (phenolic) phase. Both virgin and charred PICA showed greater strength values compared to FiberForm coupons, confirming that the presence of the porous matrix helps in absorbing the fracture energy.

Agrawal, Parul↗

Impact of NASA’s Entry Systems Modeling Project on Planetary Mission Design

Planetary missions continue to grow larger and more complex. Furthermore, the current focus on human exploration of the Moon and Mars, as well as Mars Sample Return(MSR), place increas-ingly stringent requirements on the reliability of the entry, descent, and landing (EDL) system that ensures the safe delivery of payload or crew to their destination. Planetary EDL is an area in which mission designers are critically reliant on modeling and simulation to demonstrate the reliability of the system, as there are no ground facilities that are able to fully test these systems in a flight-relevant environment. NASA’s state-of-the-art modeling and simulation capability must continually evolve to meet the needs of the next generation of planetary EDL. To accomplish this aim, NASA’s Entry Systems Modeling (ESM) Project was formed in 2013and is funded bythe Space Technology Mission Directorate(STMD) and Science Mission Directorate (SMD). ESM is the Agency’s only cross-cutting effort for advancing entry systems modeling and simulation capabilities across a range of technical disciplines and Solar System destinations. ESM is a portfolio project covering a variety of mid-TRL research efforts within four core EDL-related areas of investment: (1) Thermal protection material modeling, (2) Shock layer kinetics and radiation, (3) Aerosciences, and (4) Guidance, navigation, and con-trol. The material modeling group creates detailed material response modelsof thermal protection systems (TPS)from the micro to macro scale, and at the fun-damental and engineering levels. Shock layer kinetics and radiation focuses on radiative heating of space-craft, quantum chemistry and benchmark experiments for validation.Aerosciences is a broad research area that impacts many aspects of entry systems, including parachutes, aerodynamics, and turbulent heating augmentation due to TPS roughness.The guidance, navigation,and control effort under ESM is expanding the capabilities of NASA’s main flight mechanics tool, POST2, for use on high-performance computing architectures and to generalize interoperability with external applications for more detailed end-to-end simula-tion.In addition, several focusedresearch topics have been approvedto augment ESM’s core portfolio. These include efforts for deep post-flight analysis of Mars 2020/MEDLI2 flight data; development ofTPS failure models; improvement of hypersonic wakeflow models; and a recently concluded effort to provide material response models for NuSil-coated PICA heat-shield material. This presentation will discuss each of these investment areas and demonstrate via real mission examples how advances to the state-of-the-art enabled by ESM are directly impacting the missions of today and tomorrow, including InSight, Mars 2020, Mars Sample Return, Orion, and Dragonfly.

Entry Systems Modeling↗

Effects of natural environment on first generation solid rocket booster thermal protection system materials

The effort to demonstrate, by real-time exposure, the effects of the natural environment at Kennedy Space Center, Florida, upon the Thermal Protection System (TPS) of the Solid Rocket Booster (SRB) is summarized, and that the overall SRB TPS configuration is verified to meet all requirements for resistance to the conditions associated with outdoor weathering, including: solar radiation; temperature; humidity; precipitation; wind; sand/dust abrasion; static electricity; salt spray; fungus; and atmospheric oxidants. The evaluation criterion for this project was based upon flatwise tensile properties, visual inspection, color change, and thermal performance. Based upon the evaluation of the changes in these properties, it is concluded that properly applied and topcoat-protected TPS can satisfactorily withstand the conditions of the natural environment at KSC for exposures up to six months.

Webb, D. D.↗

Development of Advanced Lightweight Polymeric Foam Thermal Protection for Space Launch Vehicles

Lightweight thermal protective materials are essential for temperature regulation during ascent of space launch vehicles, especially for expendable launch vehicles and cryogenic propellant tanks. Among the lightest thermal protective materials commonly in use is polymeric foam, in the form of pour foam or spray-on foam insulation (SOFI). Foam processing is rapid, can accommodate large-scale or small-scale challenging geometries easily, and can be used in a climate controlled or non-climate-controlled setting. Application systems can be fixed or portable. Use-temperatures of foam range from cryogenic to those that will ablate the material.

TPS↗

Error Sources and Mitigation Strategies for Thermocouples Integrated in Flexible Thermal Protection System Materials

Brief Presenter Biography:Ruth Miller is an aer-ospace systems engineer in the Entry Systems and Ve-hicle Development Branch at NASA Ames Research Center.Introduction:The flexible thermal protection sys-tem (FTPS) on NASA’s Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) vehicle will be in-strumented with thermocouples (TCs) to measure the in-depth thermal response during entry into Earth’s atmos-phere[1, 2]. Accurate flight temperature measurements are critical for verifying vehicle performance during the flight test and reducing uncertainties in the thermal models.However,the deployable nature of inflatable decelerator technology presents challengesfor integrat-ing TCs, specifically the TCsneed to be compactableand cannot damage the FTPSnor the inflatable structure(IS).Unlike traditional rigid aeroshells, routing TCsthrough the thickness of the FTPS could cause signifi-cant damage during packing of the deployable aeroshellbecause the different layers may shift small amounts in relation to each other imparting strain on the TCsand FTPS materials. The LOFTID TCleads are routed from the measurement location back to the data acquisition system in the vehicle centerbody within the same FTPS layer that they are monitoring the temperature. This ap-proach eliminates the need to put holes in the FTPS lay-ers,butas a consequence,the insulated TCleads travel for an appreciable distance through a region that will expose them to high temperaturesand large thermal gra-dients.LOFTID’s TCswere baselined to be commercially available Type K TCswith a binder impregnated glass braid insulation. These TCswere chosen because they had been used successfully on IRVE-3 and in ground-based arc jet testing. Additionally, these TCsdid notdamage the FTPS nor IS during packing and deploy-ment testing. However, the glass braid insulation is only rated to a maximum continuous use temperature of 482ºC. For reference, the duration of the heat pulse on the LOFTID vehicle is on the order of minutes and themaximum predicted temperaturebeneaththe outermost FTPS layersis 1350ºC.Ground-based testing in a tube furnace at NASA Ames Research Centerwas conducted to determine if the baseline TCsrouted through FTPS samples would survive and provide accurate temperature measure-mentsat LOFTID flight-relevant temperatures[3].The test results showed large measurement errors occurred beginning at approximately 400°C due to conductive deposits on the TCinsulation electrically shorting the TCleads.The conductive deposits and thus electrical shorting weredetermined to be caused by twoerror sources:1.The organic binder on the TCinsulation carbon-izingin a high temperature, low oxygen envi-ronment2.Decomposition products from the FTPSperme-atingthe braided TC insulationFurther testing in the tube furnace demonstrated that heat cleaning the TCinsulation effectivelyremovedthe organic binder andeliminatedthe first error source.The second error sourcewas shown to be mitigated by the addition of amica wraparound each individual TCleadtoact as an impermeable barrier.To understand the applicability of theground-based tube furnace test results to flight,anarc jet testseriesat Boeing’s Large Core Arc Tunnel (LCAT) facilitywas conducted[4].The error sourcesand mitigation strate-giesidentified in the tube furnace testing were substan-tiatedin the arc jet testing.However, the arc jet testing also revealed three new error sources:1.Glass TCinsulation meltingwhich resultsin electrical shorting of the TCeither through di-rect contact between the two leads or through the electrically conductive FTPS materials2.TCwire meltingwhich results in a noisy and/or open-loop TCresponse3.Type K TCwire green-rotwhich results in large calibration errors Scope of the Presentation:This presentation will include a brief discussion onthe effect of electrical shorting on the output of a TC(i.e. how to identify elec-trical shorting in TCdataand what the associated erroris).The tube furnace and arc jet test resultswill be dis-cussedand the solutions LOFTID is implementing to mitigate the error sourcesidentified in the tube furnace and arc jet testingwill be presented.Additionally, futureresearch and development work to eliminateTCerror sourcesfor future missionswill be recommended.

R A Miller↗

Particle-Based Fiber Models of Woven Materials for Earth Entry Thermal Protection

Applications requiring materials with layer-to-layer strength, from basketry to thermal protection systems, use interlaced, three-dimensional woven materials. NASA is developing and deploying woven material heat shields for missions, including Artemis I (3D-MAT for compression pads) and potentially Mars Sample Return - Earth Entry System. These materials are complex, hierarchical and must protect from extreme environments and phenomena, such as deformation, impact and high-enthalpy heating. Woven material performance depends on microstructure, damage and weave geometry. Therefore, fiber-specific models are needed to simulate fiber contacts within the weave hierarchical geometry (fiber to tow to yarn to weave) and the inherent directionality of fibers. Explicit fiber models can simulate how weave microstructure evolution affects thermal and mechanical properties. We parameterize a discrete element bonded particle models (DEM-BPM) of fibers to capture thermal and mechanical behavior within and between fibers, with bonded and contact forces, respectively. We study the proportion of heat transfer and stress via the contact network, fiber bonds and the weave geometry, for example, with respect to yarn warp-weft identity (whether it interlaces weave layers). Our results demonstrate the importance of explicit fiber modeling for connecting microstructure with thermal and mechanical properties.

woven material↗

Particle-Based Fiber Models of Woven Materials for Earth Entry Thermal Protection

Applications requiring materials with layer-to-layer strength, from basketry to thermal protection systems, use interlaced, three-dimensional woven materials. NASA is developing and deploying woven material heat shields for missions, including Artemis I (3D-MAT for compression pads) and potentially Mars Sample Return - Earth Entry System. These materials are complex, hierarchical and must protect from extreme environments and phenomena, such as deformation, impact and high-enthalpy heating. Woven material performance depends on microstructure, damage and weave geometry. Therefore, fiber-specific models are needed to simulate fiber contacts within the weave hierarchical geometry (fiber to tow to yarn to weave) and the inherent directionality of fibers. Explicit fiber models can simulate how weave microstructure evolution affects thermal and mechanical properties. We parameterize a discrete element bonded particle models (DEM-BPM) of fibers to capture thermal and mechanical behavior within and between fibers, with bonded and contact forces, respectively. We study the proportion of heat transfer and stress via the contact network, fiber bonds and the weave geometry, for example, with respect to yarn warp-weft identity (whether it interlaces weave layers). Our results demonstrate the importance of explicit fiber modeling for connecting microstructure with thermal and mechanical properties.

woven material↗

Uranus Probe Entry and Descent Mission Concept

Introduction: Uranus was identified as the third highest priority flagship mission in the 2012-2022 Planetary Science Decadal Survey. This latest concept study was requested by the Decadal Survey panel to determine NASA’s planetary science priorities from 2022-2032. This study focused on the probe’s entry and descent aspects and associated trades for viable trajectory options. Uranus Mission and Descent Probe: The proposed Uranus Orbiter and Probe (UOP) Flagship mission will investigate Uranus and its surrounding moons using an orbiting spacecraft with a Uranus descent probe. Unlike previous studies the probe release will occur after orbit insertion allowing sufficient separation of critical events during the orbit insertion burn. The probe will be released at an altitude that allows one hour of in situ atmospheric readings that will be relayed to the orbiter. Afterwards the orbiter will transition to the moon tour phase of the mission. The configuration chosen for the entry aeroshell was a 45° sphere-cone. This shape has been used in the past in the Pioneer Venus Galileo missions. However, the nose radius considered in the present study differed from the values used in either of the previous configurations, primarily to reduce the heat flux at the stagnation point. A two-step approach was used in the development of flight trajectories for the chosen configuration. In the first step, the trajectory code POST2 was used to screen the thousands of entry states provided by interplanetary trajectory simulations, which were terminated at an altitude of 2000 km from the reference surface (1 bar) of Uranus. The screening criteria were: (i) optimization of the communication geometry between the entry probe and orbiter to ensure at least 1 hour of science measurements, (ii) peak stagnation point pressures to be less than six bar, (iii) peak heat fluxes to be less than 5 kW/cm2; the latter two constraints being the limits of ground-test capabilities of the arc jets at NASA Ames Research Center. The entry team investigated two trajectories that met the criteria above, a shallow entry (high heat load ~44 kJ/cm2) and a steeper entry (high heat rate ~1950 W/cm2). In the second step, the two bounding candidate entry states from the POST2 screening process were used in developing flight trajectories using TRAJ coupled with FIAT (a materials thermal response and sizing code) and a margins policy to determine a margined uniform thickness (hence mass) of the forward heatshield material based on the aerothermal environments at the stagnation point. Since the combination of TRAJ and FIAT size the TPS based on stagnation point environments only, flow field computations using DPLR were necessary to determine turbulent aerothermal environments on the conical flank, and the augmentation of these environments due to surface roughness. The environments at select locations on the forward heatshield were then used to size the thermal protection material, with the largest thickness value then used to estimate the mass. The newly developed woven thermal protection material –HEEET (Heatshield for Extreme Entry Environments Technology) –was considered for the forward heatshield and PICA (Phenolic-Impregnated Carbon Ablator) was considered for the backshell. These NASA-developed materials are at TRL 6 and TRL 9, respectively. Furthermore, two options were considered for the HEEET material: (i) a dual-layer option with a denser recession layer on top and an insulative layer underneath it, and (ii) a single layer option consisting of the insulative layer alone. Results: It is clear that probe entry states are feasible and the selected TPS options are able to perform in the predicted aerothermal environments thus enabling the mission to meet of the descent probe portion of this flagship mission

Entry Descent and Landing↗

AERACEPT (AErosol Rapid Analysis Combined Entry Probe/sonde Technology) for the Nephele Venus Cloud Mission Concept

Nephele is a small atmospheric probe mission concept to determine whether the Venus clouds contain organic matter. Nephele complements larger missions that seek to conduct Venus atmospheric analyses, such as DAVINCI, Venera-D, and the Morning Star missions, by directly sampling and analyzing cloud and haze particles. AERACEPT is an aerosol sampling technology designed to minimize the mass, volume, and complexity required for in situ planetary atmosphere characterization. A single aeroshell functions as a combined entry vehicle, descent probe, and instrumented sonde, combining recent advances in thermal protection materials with heritage technology from planetary and airborne science. The velocity of descent drives aerosol through inlets embedded in the aeroshell’s thermal protection material; inertial separation isolates the particles from the gas stream; and the particle capture surface doubles as the analysis substrate. This method can work without heat shield separation, descent control, or active sample handling; these advantages trade against a smaller sample volume, higher risk of sample heating, and shorter time for analysis and data return. AERACEPT further benefits from modeling of the internal and external flow to understand the particle capture efficiency and bias for size and concentration distributions. AERACEPT is well suited for a Venus mission such as Nephele, where a passive descent trajectory is both subsonic over the altitudes of interest and provides sufficient velocity and pressure differential for the particle sizes of interest. A thermal and flow toolchain developed in-house (Traj→ DPLR→ PATO→ openFOAM) was used to model an 80-cm aeroshell with science operations 63–39 km. These models indicate that AERACEPT will provide ~24 µL accumulated sample of particles ≥ 0.2 µm, substantially above the 2 µL threshold requirement. The worst-case particle heating will be ~14 K above ambient, for the smallest particles at the lowest altitude; most particles will experience ≤ 1 K rise, at which almost all analytes of interest will be unaffected. Plasma jet testing of a small-scale aeroshell-material inlet was recently conducted to validate the thermal model parameters; wind tunnel testing to validate the flow model parameters is underway.

AERACEPT↗

Aerothermodynamic design feasibility of a Mars aerocapture/aeromaneuver vehicle

Lifting aerodynamic configurations have been screened and selected for the Mars aerocapture mission that (1) meet the geometric packaging requirements of the various payloads and the Space Shuttle cargo bay and (2) provide the aerodynamic performance characteristics required to obtain the atmospheric exit steering accuracy and the parachute deployment conditions desired. Hypersonic heat transfer and aerodynamic loads to the vehicle in the CO2 atmosphere are evaluated. Contemporary low density ablative thermal protection materials were selected that meet all the atmospheric entry requirements and provide a minimum mass solution. Results are presented of the aerodynamic configuration and thermal protection materials screening and selection. It is concluded that the aerothermodynamic design of this concept is feasible using state-of-the-art technology.

Florence, D. E.↗

SRB thermal protection systems materials test results in an arc-heated nitrogen environment

The external surface of the Solid Rocket Booster (SRB) will experience imposed thermal and shear environments due to aerodynamic heating and radiation heating during launch, staging and reentry. This report is concerned with the performance of the various TPS materials during the staging maneuver. During staging, the wash from the Space Shuttle Main Engine (SSME) exhust plumes impose severe, short duration, thermal environments on the SRB. Five different SRB TPS materials were tested in the 1 MW Arc Plasma Generator (APG) facility. The maximum simulated heating rate obtained in the APG facility was 248 Btu/sq ft./sec, however, the test duration was such that the total heat was more than simulated. Similarly, some local high shear stress levels of 0.04 psia were not simulated. Most of the SSME plume impingement area on the SRB experiences shear stress levels of 0.02 psia and lower. The shear stress levels on the test specimens were between 0.021 and 0.008 psia. The SSME plume stagnation conditions were also simulated.

Wojciechowski, C. J.↗

Effects of Laser Wavelength on Ablator Testing

Wavelength-dependent or spectral radiation effects are potentially significant for thermal protection materials. NASA atmospheric entry simulations include trajectories with significant levels of shock layer radiation which is concentrated in narrow spectral lines. Tests using two different high powered lasers, the 10.6 micron LHMEL I CO2 laser and the near-infrared 1.07 micron fiber laser, on low density ablative thermal protection materials offer a unique opportunity to evaluate spectral effects. Test results indicated that the laser wavelength can impact the thermal response of an ablative material, in terms of bond-line temperatures, penetration times, mass losses, and char layer thicknesses.

thermal protection↗

Technology Development and Infusion by NASA's Entry Systems Modeling Project

This paper describes recent development of modeling and simulation technologies for entry systems and their infusion into NASA's exploration missions. Technology development is organized and prioritized using a system-level perspective, resulting in four broad technical areas of investment: (1) Thermal protection material modeling, (2) Shock layer kinetics and radiation, (3) Computational and experimental aerosciences, and (4) Guidance, navigation, and control. The paper will highlight key contributions from each of these areas, their impacts from a spacecraft and mission design perspective, and discuss planned future investment. Aspects of each technical area are only briefly summarized here. Thermal protection material modeling is geared toward high-fidelity, predictive models capable of optimizing design performance, post-flight reconstruction, and quantifying thermal protection system reliability. New computational tools and experimental techniques have been applied to Orion, MSL/Mars 2020, Mars InSight, and Mars Sample Return missions. Research and development in the area of shock layer kinetics has focused on air and CO2-based atmospheres. In both cases, substantial improvements in model uncertainty have directly impacted the development of mission margin policies, flight instrumentation design and analysis (Orion and Mars 2020), and have even revealed the importance of neglected phenomena like mid-wave infrared radiation of CO2. Aerosciences is a very broad area of interest in entry systems, yet a number of important challenges are being addressed: Coupled fluid-structure simulations of parachute inflation and dynamics affecting Orion, Commercial Crew, and Mars programs; Experimental and computational studies of vehicle dynamics; Multi-phase flow with dust particles to simulate augmentation of aerothermal environments at Mars during dust storms; and studies of roughness-induced heating augmentation relevant to tiled (Orion, Mars 2020) and woven (Mars Sample Return) thermal protection systems. Guidance and control in the context of entry systems has focused on development of methods for multi-axis control (i.e. pitch and yaw, rather than bank angle alone) of spacecraft during entry and descent, with precision landing requirements driven by Mars human exploration goals.

Barnhardt, Michael D.↗

Material Properties for Fiber-Reinforced Silica Aerogels

Ceramic fiber-reinforced silica aerogels are novel materials for high performance insulation, including thermal protection materials. Experimental data are presented for the thermal and mechanical properties, showing the trends exhibited over a range of fiber loadings and silica aerogel densities. Test results are compared to that of unreinforced bulk aerogels.

White, Susan↗

Sustaining PICA for Future NASA Robotic Science Missions Including NF-4 and Discovery

Phenolic Impregnated Carbon Ablator (PICA), invented in the mid 1990's, is a low-density ablative thermal protection material proven capable of meeting sample return mission needs from the moon, asteroids, comets and other unrestricted class V destinations as well as for Mars. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. It is important that NASA maintain this thermal protection material capability and ensure its availability for future NASA use. The rayon based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years and a third substitution is now needed. The carbon precursor replacement challenge is twofold - the first involves finding a long-term replacement for the current rayon and the second is to assess its future availability periodically to ensure it is sustainable and be alerted if additional replacement efforts need to be initiated. This paper reviews current PICA sustainability activities to identify a rayon replacement and to establish that the capability of the new PICA derived from an alternative precursor is in family with previous versions.

Stackpoole, Mairead↗

Sustaining PICA for Future NASA Robotic Science Missions Including NF-4 and Discovery

Phenolic Impregnated Carbon Ablator (PICA), invented in the mid 1990's, is a low-density ablative thermal protection material proven capable of meeting sample return mission needs from the moon, asteroids, comets and other unrestricted class V destinations as well as for Mars. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. It is important that NASA maintain this thermal protection material capability and ensure its availability for future NASA use. The rayon based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years and a third substitution is now needed. The carbon precursor replacement challenge is twofold - the first involves finding a long-term replacement for the current rayon and the second is to assess its future availability periodically to ensure it is sustainable and be alerted if additional replacement efforts need to be initiated. This paper reviews current PICA sustainability activities to identify a rayon replacement and to establish that the capability of the new PICA derived from an alternative precursor is in family with previous versions.

Stackpoole, Mairead↗