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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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NASA NTRS2002

Fundamental Mixing and Combustion Experiments for Propelled Hypersonic Flight

Two experiments have been conducted to acquire data for the validation of computational fluid dynamics (CFD) codes used in the design of supersonic combustors. The first experiment is a study of a supersonic coaxial jet into stagnant air in which the center jet is of a light gas, the coflow jet is of air, and the mixing layer between them is compressible. The jet flow field is characterized using schlieren imaging, surveys with Pitot, total temperature and gas sampling probes, and RELIEF velocimetry. VULCAN, a structured grid CFD code, is used to solve for the nozzle and jet flow. The second experiment is a study of a supersonic combustor consisting of a diverging duct with single downstream-angled wall injector. Entrance Mach number is 2 and enthalpy is nominally that of Mach 7 flight. Coherent anti-Stokes Raman spectroscopy (CARS) has been used to obtain nitrogen temperature in planes of the flow, and surface pressures and temperatures have also been acquired. Modern-design-of-experiment techniques have been used to maximize the quality of the data set.

Cutler, A. D.↗
NASA NTRS2003

Commercial Research Results from the International Space Station

As part of NASA's mission of enabling commercial opportunities in space, the Space Product Development Office has sponsored the flight of twelve commercial payloads to the International Space Station (ISS) during calendar year 2002. These twelve follow seven commercial payloads flown to the ISS during 2001. Many of these payloads, which were among the first users of this new laboratory, built upon successful commercial investigations that previously were restricted to the limited flight duration of the Space Shuttle. While the majority of early commercial use of the ISS is in the area of biotechnology, there is a significant shift towards commercial materials research over the next two years. New commercial payloads such as Space-DRUMS and Vulcan will advance commercial materials research on the ISS. Commercial flight hardware is available to the broader NASA community in order to provide benefit to the entire NASA microgravity program, and the scientific community on a space available basis and at very low cost. The first commercial operations on the ISS provides not only a needed capability to the commercial development of space program, it will also augment the science program as well.

Nall, Mark↗
NASA NTRS2003

Computational Fluid Dynamics Technology for Hypersonic Applications

Several current challenges in computational fluid dynamics and aerothermodynamics for hypersonic vehicle applications are discussed. Example simulations are presented from code validation and code benchmarking efforts to illustrate capabilities and limitations. Opportunities to advance the state-of-art in algorithms, grid generation and adaptation, and code validation are identified. Highlights of diverse efforts to address these challenges are then discussed. One such effort to re-engineer and synthesize the existing analysis capability in LAURA, VULCAN, and FUN3D will provide context for these discussions. The critical (and evolving) role of agile software engineering practice in the capability enhancement process is also noted.

Gnoffo, Peter A.↗
NASA NTRS1999

A Pseudo-Temporal Multi-Grid Relaxation Scheme for Solving the Parabolized Navier-Stokes Equations

A multi-grid, flux-difference-split, finite-volume code, VULCAN, is presented for solving the elliptic and parabolized form of the equations governing three-dimensional, turbulent, calorically perfect and non-equilibrium chemically reacting flows. The space marching algorithms developed to improve convergence rate and or reduce computational cost are emphasized. The algorithms presented are extensions to the class of implicit pseudo-time iterative, upwind space-marching schemes. A full approximate storage, full multi-grid scheme is also described which is used to accelerate the convergence of a Gauss-Seidel relaxation method. The multi-grid algorithm is shown to significantly improve convergence on high aspect ratio grids.

White, J. A.↗
NASA NTRS2005

Validation of the NCC Code for Staged Transverse Injection and Computations for a RBCC Combustor

The NCC code was validated for a case involving staged transverse injection into Mach 2 flow behind a rearward facing step. Comparisons with experimental data and with solutions from the FPVortex code was then used to perform computations to study fuel-air mixing for the combustor of a candidate rocket based combined cycle engine geometry. Comparisons with a one-dimensional analysis and a three-dimensional code (VULCAN) were performed to assess the qualitative and quantitative performance of the NCC solver.

Ajmani, Kumud↗
NASA NTRS2006

Single-Pulse Multi-Point Multi-Component Interferometric Rayleigh Scattering Velocimeter

A simultaneous multi-point, multi-component velocimeter using interferometric detection of the Doppler shift of Rayleigh, Mie, and Rayleigh-Brillouin scattered light in supersonic flow is described. The system uses up to three sets of collection optics and one beam combiner for the reference laser light to form a single collimated beam. The planar Fabry-Perot interferometer used in the imaging mode for frequency detection preserves the spatial distribution of the signal reasonably well. Single-pulse multi-points measurements of up to two orthogonal and one non-orthogonal components of velocity in a Mach 2 free jet were performed to demonstrate the technique. The average velocity measurements show a close agreement with the CFD calculations using the VULCAN code.

Bivolaru, Daniel↗
NASA NTRS2002

Fundamental Mixing and Combustion Experiments for Propelled Hypersonic Flight

The first experiment is a study of a coaxial jet discharging into stagnant laboratory air, with center jet of a mixture of 5% oxygen and 95% helium by volume and coflow jet of air. The exit flow pressure of both center-jet and coflow nozzles is 1 atmosphere. The presence of oxygen in the center jet is to allow the use of an oxygen flow-tagging technique (RELIEF4) to obtain non-intrusive velocity measurements. Both jets are nominally Mach 1.8, but, because of the greater speed of sound, the center jet velocity is more than twice that of the coflow. The mixing layer which forms between the center jet and the coflow near the nozzle exit is compressible, with a calculated convective Mach number of approximately 0.7. This geometry has several advantages: The streamwise development of the flow is generally dominated by turbulent stresses (rather than pressure forces), and thus calculations are sensitive to turbulence modeling. It includes features present in supersonic combustors, including a compressible mixing layer near the nozzle exit and a light-gas/air plume downstream. Since it is a free jet, it provides easy access for both optical instrumentation and probes. Since it is axisymmetric, it requires fewer experimental measurements to fully characterize, and calculations can be performed with more modest computer resources. However, weak shock waves formed at the nozzle exit strengthen and turn normal as they approach the axis, complicating the flow. Care is thus taken in the design of the facility to provide as near as possible to 1-D flow at the exit of both center and coflow nozzles, and to minimize the strength of waves generated at the nozzle exit. Results from this experiment are compared to CFD solutions obtained by VULCAN, a previously developed code used in engine analysis. The second experiment is a study of a supersonic combustor consisting of a diverging duct with single downstream-angled wall injector. Thus, the geometry is relatively simple and large regions of subsonic recirculating flow are avoided. The nominal entrance Mach number is 2 and the enthalpy of the test gas (hot air "simulant") is nominally that of Mach 7 flight. It was believed, on the basis of calculations performed that this would produce mixing-limited flow, that is to say, one for which chemical reaction to equilibrium proceeds at a much greater rate than mixing. It later proved that this was not the case. The primary experimental technique employed is coherent anti-Stokes Raman spectroscopy, known by its acronym CARS. The species probed is molecular nitrogen and the quantity measured is temperature. Intrusive probes, such as Pitot, total temperature, hot-wire, etc., are not used due to access difficulty and high heat flux in the combustor, and because they may alter the flow. CARS has several advantages over other optical methods. It is a relatively mature and well-understood technique. Signal levels are relatively high and the signal is in the form of a coherent (laser) beam that can be collected through small windows. Incoherent (non-CARS) interferences are rejected by spatial filtering.

Diskin, G. S.↗
NASA NTRS2007

A Supersonic Argon/Air Coaxial Jet Experiment for Computational Fluid Dynamics Code Validation

A non-reacting experiment is described in which data has been acquired for the validation of CFD codes used to design high-speed air-breathing engines. A coaxial jet-nozzle has been designed to produce pressure-matched exit flows of Mach 1.8 at 1 atm in both a center jet of argon and a coflow jet of air, creating a supersonic, incompressible mixing layer. The flowfield was surveyed using total temperature, gas composition, and Pitot probes. The data set was compared to CFD code predictions made using Vulcan, a structured grid Navier-Stokes code, as well as to data from a previous experiment in which a He-O2 mixture was used instead of argon in the center jet of the same coaxial jet assembly. Comparison of experimental data from the argon flowfield and its computational prediction shows that the CFD produces an accurate solution for most of the measured flowfield. However, the CFD prediction deviates from the experimental data in the region downstream of x/D = 4, underpredicting the mixing-layer growth rate.

Clifton, Chandler W.↗
NASA NTRS2008

Direct-View Multi-Point Two-Component Interferometric Rayleigh Scattering Velocimeter

This paper describes an instantaneous velocity measurement system based on the Doppler shift of elastically scattered laser light from gas molecules (Rayleigh scattering) relative to an incident laser. The system uses a pulsed laser as the light source, direct-viewing optics to collect the scattered light, an interferometer to analyze spectrally the scattered light mixed with the incident laser light, and a CCD camera to capture the resulting interferogram. The system is capable of simultaneous, spatially (approximately 0.2 mm(exp 3)) and temporally (approximately 40 ns) resolved, multiple point measurements of two orthogonal components of flow velocity in the presence of background scattered light, acoustic noise and vibrations, and flow particulates. Measurements in a large-scale axi-symmetric Mach 1.6 H2-air combustion-heated jet running at a flow sensible enthalpy specific to Mach 5.5 hypersonic flight are performed to demonstrate the technique. The measurements are compared with CFD calculations using a finite-volume discretization of the Favre-averaged Navier-Stokes equations (VULCAN code).

Bivolaru, Daniel↗
NASA NTRS2009

Spatially and Temporally Resolved Measurements of Velocity in a H2-air Combustion-Heated Supersonic Jet

This paper presents simultaneous measurements at multiple points of two orthogonal components of flow velocity using a single-shot interferometric Rayleigh scattering (IRS) technique. The measurements are performed on a large-scale Mach 1.6 (Mach 5.5 enthalpy) H2-air combustion jet during the 2007 test campaign in the Direct Connect Supersonic Combustion Test facility at NASA Langley Research Center. The measurements are performed simultaneously with CARS (Coherent Anti-stokes Raman Spectroscopy) using a combined CARS-IRS instrument with a common path 9-nanosecond pulsed, injection-seeded, 532-nm Nd:YAG laser probe pulse. The paper summarizes the measurements of velocities along the core of the vitiated air flow as well as two radial profiles. The average velocity measurement near the centerline at the closest point from the nozzle exit compares favorably with the CFD calculations using the VULCAN code. Further downstream, the measured axial velocity shows overall higher values than predicted with a trend of convergence at further distances. Larger discrepancies are shown in the radial profiles.

Bivolaru, Daniel↗
NASA NTRS2008

Rapid Biochemical Analysis on the International Space Station (ISS): Preparing for Human Exploration of the Moon and Mars

The Lab-on-a-Chip Application Development - Portable Test System, known as LOCAD-PTS, was launched to the International Space Station (ISS) aboard Space Shuttle Discovery (STS-116) on December 9th,2006. Since that time, it has remained onboard ISS and has been operated by the crew on 10 separate occasions LOCAD-PTS is a handheld device for rapid biochemical analysis; it consists of a spectrophotometer, a series of interchangeable cartridges, a pipette and several clean/sterilized swabbing kits to obtain samples from ISS surfaces. Sampling, quantitative analysis and data retrieval is performed onboard, therefore reducing the need to return samples to Earth. Less than 20 minutes are required from sampling to data, significantly faster than existing culture-based methods on ISS, which require 3-5 days. Different cartridges are available for the detection of different target molecules (simply by changing the formulation within each cartridge), thereby maximizing the benefit and applications addressed by a single instrument. Initial tests on ISS have focused on the detection of the bact.erial macromolecule endotoxin, a component of bacterial cell walls. LOCAD-PTS detects endotoxin with a cartridge that contains a formulation known as Limulus Amebocyte Lysate (LAL) assay. LAL is derived from blood of the horseshoe crab, Limulus polyphemus, and detects enodotoxin with an enzyme cascade that triggers generation Of a yellow colored dye, p-nitroanaline. The more p-nitroanaline product, the more endotoxin is in the original sample. To enable quantitative analysis, the absorbance of this color is measured by LOCAD-PTS through a 395 nm filter and compared with an internal calibration curve, to provide a reading on the LED display that ranges from 0.05 Endotoxin Units (EU)/ml to 5 EU/ml. Several surface sites were analyzed within ISS between March 2007 and February 2008, including multiple locations in the US Laboratory Destiny, Node 1 Unity, AMock, and Service Module Zvezda. The goals of this initial study were to i) test the cleanliness of reagents/supplies on orbit, ii) test the crew's ability to collect and process a sample in microgravity without contamination, iii) demonstrate nominal function of the LOCAD-PTS, and iv) provide a general survey of endotoxin within the ISS. The surface sites varied greatly in terms of their frequency-of-use and material texture/composition; from relatively smooth aluminum, to fabric, to the room temperature vulcanizing (RTV) rubber of a Extravehicular Mobility Unit (EMU) spacesuit. Results showed that: i) the swabbing kits and reagents remained clean on orbit, ii) the crew could collect and process a sample without contamination, and iii) the LOCAD-PTS functioned nominally in > 99% of the 55 tests completed. We will present detailed results of the survey of endotoxin on ISS surfaces. These results and technology are important in the near-term - by providing an extra tool in the toolbox for ISS microbial monitoring. They are also important in the longer term as valuable preparation for human exploration of the Moon and Mars. One of the proposed science goals for the human exploration of Mars will be to detect and characterize any indigenous biological molecules that may exist on the Martian surface. To achieve that goal, the crew must have the technology available onboard to differentiate indigenous biology from any terrestrial biological material brought to Mars by the spacecraft and crew (termed 'forward contamination'). The LAL assay is already one of the official methods used by NASA's planetary protection program to certify cleanliness of interplanetary robotic spacecraft prior to launch; and therefore endotoxin is a good marker of forward contamination (as well as other microbial molecules detectable with LOCAD-PTS e.g. box-1, 3-glucan and lipoteichoic acid). Furthermore, the distribution and abundance of these molecules on the ISS provides a good indicator of what to expect on the Crew Exploratioehicle Orion, the lunar lander Antares, and future crewed spacecraft destined for Mars. In addition, technology such as LOCAD-PTS has been proposed to help evaluate forward contamination during lunar surface operations by the crew, as preparation for the human exploration of Mars.

Maule, J.↗
NASA NTRS2010

Highly Siderophile Elements as Tracers for the Subcontinental Mantle Evolution Beneath the Southwestern USA: The San Carlos and Kilbourne Hole Peridotite Xenoliths Revisited

Peridotite xenoliths from San Carlos, Arizona, and Kilbourne Hole, New Mexico, have been studied since the 1970 s to give insights into melting and metasomatism in the subcontinental mantle beneath the southwestern USA. More recently, the highly siderophile elements (HSE; Os, Ir, Ru, Rh, Pt, Pd, and Re) and the included Re-Os isotope system have been established as powerful tools for the study of mantle processes because of their range in compatibility during mantle melting and their siderophile and chalcophile geochemical behavior. Model aluminachron Re-Os ages for San Carlos and Kilbourne Hole, as well as for the nearby Dish Hill and Vulcan's Throne sites, give consistent depletion ages of around 2.2 Ga. This age can be interpreted as a single large scale mantle melting event linked to crustal formation and continental growth under the southwestern USA. Highly siderophile elements, however, may be added to depleted peridotites via melt-rock interaction, especially the more incompatible and hence mobile Pt, Pd, and Re. This may result in overprinting of the signature of melt extraction, thus abating the usefulness of Re-Os mantle extraction model ages. A comprehensive characterization of the suite of mantle xenoliths from the SW USA in terms of HSE concentrations is thus necessary to re-assess the Re-Os system for dating purposes. San Carlos peridotites are depleted to moderately fertile, as indicated by their bulk Al2O3 contents between 0.66 wt% and 3.13 wt%. Bulk Os-187/Os-188 in San Carlos peridotites range from 0.1206 to 0.1357. In contrast, Kilbourne Hole peridotites tend to be more fertile with Al2O3 between 2.11 and 3.78 wt%, excluding one extremely depleted sample with 0.30 wt% Al2O3, and have Os-187/Os-188 between 0.1156 and 0.1272, typical for mantle peridotites. No large fractionation between the more compatible HSE Os, Ir, and Ru are observed. The more incompatible HSE Re, Pd, and to a minor extent, Pt, however, are depleted in a number of samples by factors of up to 4 for Pt, 6 for Pd, and 20 for Re, compared to primitive mantle estimates. This is in agreement with previous studies from the same locales, which demonstrated the presence of different populations of mantle xenoliths having undergone various degrees of melt extraction. The depletion of the more incompatible elements (Re, Pd, and Pt) also suggests that the HSE budgets of the SW USA peridotites were primarily established by extraction of basaltic melt, and reflect only minor influence from later episodes of metasomatism. Model Re-Os ages obtained from San Carlos and Kilbourne Hole xenoliths may thus reflect ages of crustal formation and mantle depletion in the SW USA region.

vanAcken, D.↗
NASA NTRS2012

Study of Forebody Injection and Mixing with Application to Hypervelocity Airbreathing Propulsion

The use of premixed, shock-induced combustion in the context of a hypervelocity, airbreathing vehicle requires effective injection and mixing of hydrogen fuel and air on the vehicle forebody. Three dimensional computational simulations of fuel injection and mixing from flush-wall and modified ramp and strut injectors are reported in this study. A well-established code, VULCAN, is used to conduct nonreacting, viscous, turbulent simulations on a flat plate at conditions relevant to a Mach 12 flight vehicle forebody. In comparing results of various fuel injection strategies, it is found that strut injection provides the greatest balance of performance between mixing efficiency and stream thrust potential.

Axdahl, Erik↗
NASA NTRS2012

Low-Dissipation Advection Schemes Designed for Large Eddy Simulations of Hypersonic Propulsion Systems

The 2nd-order upwind inviscid flux scheme implemented in the multi-block, structured grid, cell centered, finite volume, high-speed reacting flow code VULCAN has been modified to reduce numerical dissipation. This modification was motivated by the desire to improve the codes ability to perform large eddy simulations. The reduction in dissipation was accomplished through a hybridization of non-dissipative and dissipative discontinuity-capturing advection schemes that reduces numerical dissipation while maintaining the ability to capture shocks. A methodology for constructing hybrid-advection schemes that blends nondissipative fluxes consisting of linear combinations of divergence and product rule forms discretized using 4th-order symmetric operators, with dissipative, 3rd or 4th-order reconstruction based upwind flux schemes was developed and implemented. A series of benchmark problems with increasing spatial and fluid dynamical complexity were utilized to examine the ability of the candidate schemes to resolve and propagate structures typical of turbulent flow, their discontinuity capturing capability and their robustness. A realistic geometry typical of a high-speed propulsion system flowpath was computed using the most promising of the examined schemes and was compared with available experimental data to demonstrate simulation fidelity.

White, Jeffrey A.↗
NASA NTRS2012

Reynolds-Averaged Turbulence Model Assessment for a Highly Back-Pressured Isolator Flowfield

The use of computational fluid dynamics in scramjet engine component development is widespread in the existing literature. Unfortunately, the quantification of model-form uncertainties is rarely addressed with anything other than sensitivity studies, requiring that the computational results be intimately tied to and calibrated against existing test data. This practice must be replaced with a formal uncertainty quantification process for computational fluid dynamics to play an expanded role in the system design, development, and flight certification process. Due to ground test facility limitations, this expanded role is believed to be a requirement by some in the test and evaluation community if scramjet engines are to be given serious consideration as a viable propulsion device. An effort has been initiated at the NASA Langley Research Center to validate several turbulence closure models used for Reynolds-averaged simulations of scramjet isolator flows. The turbulence models considered were the Menter BSL, Menter SST, Wilcox 1998, Wilcox 2006, and the Gatski-Speziale explicit algebraic Reynolds stress models. The simulations were carried out using the VULCAN computational fluid dynamics package developed at the NASA Langley Research Center. A procedure to quantify the numerical errors was developed to account for discretization errors in the validation process. This procedure utilized the grid convergence index defined by Roache as a bounding estimate for the numerical error. The validation data was collected from a mechanically back-pressured constant area (1 2 inch) isolator model with an isolator entrance Mach number of 2.5. As expected, the model-form uncertainty was substantial for the shock-dominated, massively separated flowfield within the isolator as evidenced by a 6 duct height variation in shock train length depending on the turbulence model employed. Generally speaking, the turbulence models that did not include an explicit stress limiter more closely matched the measured surface pressures. This observation is somewhat surprising, given that stress-limiting models have generally been developed to better predict shock-separated flows. All of the models considered also failed to properly predict the shape and extent of the separated flow region caused by the shock boundary layer interactions. However, the best performing models were able to predict the isolator shock train length (an important metric for isolator operability margin) to within 1 isolator duct height.

Baurle, Robert A.↗
NASA NTRS2012

Regolith-Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication

In this paper we will discuss a new mass-efficient and innovative way of protecting high-mass spacecraft during planetary Entry, Descent & Landing (EDL). Heat shields fabricated in situ can provide a thermal-protection system (TPS) for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from regolith materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Two regolith processing and manufacturing methods will be discussed: 1) Compression and sintering of the regolith to yield low density materials; 2) Formulations of a High-temperature silicone RTV (Room Temperature Vulcanizing) compound are used to bind regolith particles together. The overall positive results of torch flame impingement tests and plasma arc jet testing on the resulting samples will also be discussed.

Hogue, Michael D.↗
NASA NTRS2012

Deformation and Phase Transformation Processes in Polycrystalline NiTi and NiTiHf High Temperature Shape Memory Alloys

The deformation and transformation mechanisms of polycrystalline Ni49.9Ti50.1 and Ni50.3Ti29.7Hf20 (in at.%) shape memory alloys were investigated by combined experimental and modeling efforts aided by an in situ neutron diffraction technique at stress and temperature. The thermomechanical response of the low temperature martensite, the high temperature austenite phases, and changes between these two states during thermomechanical cycling were probed and reported. In the cubic austenite phase, stress-induced martensite, deformation twinning and slip processes were observed which helped in constructing a deformation map that contained the limits over which each of the identified mechanisms was dominant. Deformation of the monoclinic martensitic phase was also investigated where the microstructural changes (texture, lattice strains, and phase fractions) during room-temperature deformation and subsequent thermal cycling were compared to the bulk macroscopic response. When cycling between these two phases, the evolution of inelastic strains, along with the shape setting procedures were examined and used for the optimization of the transformation properties as a function of deformation levels and temperatures. Finally, this work was extended to the development of multiaxial capabilities at elevated temperatures for the in situ neutron diffraction measurements of shape memory alloys on the VULCAN Diffractometer at Oak Ridge National Laboratory.

Benafan, Othmane↗
NASA NTRS2012

Regolith Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication

This NIAC project investigated an innovative approach to provide heat shield protection to spacecraft after launch and prior to each EDL thus potentially realizing significant launch mass savings. Heat shields fabricated in situ can provide a thermal-protection system for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Regolith has extremely good insulating properties and the silicates it contains can be used in the fabrication and molding of thermal-protection materials. Such in situ developed heat shields have been suggested before by Lewis. Prior research efforts have shown that regolith properties can be compatible with very-high temperature resistance. Our project team is highly experienced in regolith processing and thermal protection systems (TPS). Routine access to space and return from any planetary surface requires dealing with heat loads experienced by the spacecraft during reentry. Our team addresses some of the key issues with the EDL of human-scale missions through a highly innovative investigation of heat shields that can be fabricated in space by using local resources on asteroids and moons. Most space missions are one-way trips, dedicated to placing an asset in space for economical or scientific gain. However, for human missions, a very-reliable heat-shield system is necessary to protect the crew from the intense heat experienced at very high entry velocities of approximately 11 km/s at approximately Mach 33 (Apollo). For a human mission to Mars, the return problem is even more difficult, with predicted velocities of up to 14 km/s, at approximately Mach 42 at the Earth-atmosphere entry. In addition to human return, it is very likely that future space-travel architecture will include returning cargo to the Earth, either for scientific purposes or for commercial reasons. Platinum, titanium, helium 3, and other metals, elements and minerals are all high-value commodities in limited supply on Earth, and it may be profitable to mine these substances throughout the Solar System and return them to Earth, if an economical method can be found. To date, several private corporations have been launched to pursue these goals. Because the heat shield is the last element to be used in an Earth-return mission, a high penalty is paid in the propellant mass required to carry the heat shield to the destination and back. If the heat shield could be manufactured in space, and then outfitted on the spacecraft prior to the reentry at Earth, then significant propellant and mass savings could be achieved during launch and space operations. Preliminary mission architecture scenarios are described, which explain the potential benefits that may be derived from using an in-situ fabricated regolith heat shield. In order to prove that this is a feasible technology concept, this project successfully fabricated heat shield materials from mineral simulant materials of lunar and Martian regolith by two methods: 1) Sintering and 2) Binding the simulant with a "room-temperature vulcanizing" (RTV) silicone formulated to withstand high temperatures. Initially a third type of fabrication was planned using the hot waste stream from regolith ISRU processes. This fabrication method was discarded since the resulting samples would be too dense and brittle for heat shields. High temperature flame tests at KSC and subsequent arc jet tests at Ames Research Center (ARC) have proved promising. These coupon tests show favorable materials properties and have the potential to be a new way of fabricating heat shields for space entry into planetary atmospheres.

Hogue, Michael D.↗