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NASA NTRSDate not supplied

NASA Efforts to Explore Additively Manufactured Thermal Protection Systems

Development of the thermal protection system (TPS) needed to protect external and internal surfaces during launch, ascent, cruise, and reentry, is a very specialized field with expertise developed over seven decades and has enabled successful robotic as well as human exploration. Well known examples are: 1) the ablative heatshield that protected Apollo Astronauts during reentry in 1960’s, 2) reusable TPS used on the Space Shuttle Orbiter, which is now sought after by commercial space industry, and 3) hot structures, such as Carbon-Carbon and other high temperature materials needed to operate control surfaces and sharp leading edges during hypervelocity flight. TPS function demands fail-safe design to ensure mission success. One TPS does not fit all, and each application requires a unique material along with manufacturing and integration approach. TPS mass is a key metric. A robust but inefficient TPS reduces payload mass. Mission- and domain-unique TPS development and flight certification efforts have been expensive with long lead times. As a result, there are limited TPS choices with high cost. For future commercial efforts to be successful, the ability to rapidly develop TPS, based on specific needs and at a lower cost, without compromising either mass efficiency or functionality is necessary. NASA is looking into this. Additive manufacturing (AM) techniques have shown their utility in making complex parts and, through automation, the potential to reduce cost and schedule in some applications. The promise of additive manufacturing to TPS, while exciting, is unexplored. In the past several years, NASA has made exploratory investments in internal development as well as in small business and universities through SBIR and STTR programs. In addition, NASA is bringing together the TPS as well as Additive Manufacturing communities to explore approaches to prioritize focus areas for broad benefits. The very first “Additively Manufactured Thermal Protection System Workshop,” to be held at NASA Johnson Space Center in Houston at the end of March of this year, is the culmination of a year-long effort to engage the research, development, and user communities involved in both TPS as well as additive manufacturing. The workshop participants include representatives from large and small commercial space industry, DoD, Federally Funded Research and Development Centers, University Researchers and NASA personnel. The proposed talk will highlight future TPS needs of both emerging commercial and Government interests, NASA’s development efforts in additively manufactured TPS, and the findings and recommendations from the first AM TPS Workshop.

Ethiraj Venkatapathy↗
NASA NTRSDate not supplied

Recent Advances in the U.S. in Ablative TPS for In-situ Exploration of Giant Planets

The Decadal Survey report released [1] prioritizes Uranus as the highest priority Flagship class mission to be explored with an orbiter and a probe and it also recommended Saturn Probe under New Frontiers mission class. Thermal protection system (TPS) is essential for Uranus and Saturn probe missions. The two cardinal requirements are that it must be fail-safe and yet be mass efficient. The Decadal Survey report also pointed out the readiness of heatshield for extreme entry environment technology (HEEET) at TRL 6 for probe missions at Gas Giants. HEEET relies on 3-D weaving and is shown to be a robust and mass efficient TPS through ground testing and analysis. HEEET was matured to TRL 6 in 2019. HEEET was reported at the Ice Giant Workshop in 2019 at Marseille. Since 2019, significant advances have been made primarily because of Mars Sample Return (MSR) mission. MSR baselined 3-D Woven TPS as its heatshield for the earth entry system. MSR earth entry system (EES) requirements and the resulting heatshield/TPS requirements are most stringent of all entry missions. This is a result of backward contamination protection which classifies MSR as a “restricted class 5” mission to safeguard the accidental release of potentially hazardous Mars Sample into Earth’s atmosphere. Complex requirements for the heatshield start with micro-meteor impact tolerance followed by the requirement for steep entry to minimize the size of the impact footprint which results in extreme heating. The heatshield is part of the impact attenuation system. The EES architecture does not use a parachute and is designed to tolerate impact loads. Hence heatshield TPS selection and design becomes one of the key challenges. After completion of the HEEET technology maturation in 2019, IRAD efforts focused on assessing the 3-D Woven family of TPS to MSR EES. After nearly two years of evaluation of alternate TPS such as carbon phenolic, C-C hot structure, PICA, and 3-D woven family of TPS, a single layer 3-D woven TPS derived from the dual-layer HEEET was down selected and is currently the baseline. A new loom capable of weaving the single-layer 3-D woven preform at 80” wide has been designed, assembled and is currently on the verge of weaving the MSR EES TPS. During the HEEET maturation and the follow-on development, the single-layer TPS has been tested at extreme heating conditions. As a result, single layer TPS was recommended and evaluated during the Planetary Mission Concept Studies funded by NASA in preparation for the Decadal committee. In addition, in anticipation of Saturn mission proposals, single layer was evaluated as well. Aerocapture can reduce the trip time, also allow bigger payload fraction and in addition, it allows for the possibility of probe delivery once the spacecraft is in orbit. This can lead to obtaining both in-situ data as well as data from orbit simultaneously. Since Aerocapture depletes energy/velocity, probe delivery from orbit reduces the demand on TPS. Aerocapture was mentioned in the Decadal Study report as ready for implementation, but due to perceived risk it is not adopted by the mission designers. Establishing TPS readiness for aerocapture missions will be addressed. Going one step beyond aerocapture is aerogravity assist if fast return is the goal. Recent studies [4] looked at aerogravity assist and the TPS readiness. This talk will highlight both aerocapture and aerogravity assist from a TPS perspective. The main objective of this proposed talk is to present a comprehensive picture of the SOA TPS technology including recent developments. The talk will highlight advances in manufacturing, results from the Decadal White Papers, PMCS and other studies, and aerocapture and aerogravity assist that could play a role in the near or far term in-situ exploration.

E. Venkatapathy↗
DOE OSTI2023

Molten Salt Tritium Transport Experiment: A Versatile Fluoride Salt Loop for Validation of Tritium Transport Phenomena

Tritium is generated in Molten Salt Reactors (MSRs) from neutron capture by lithium and other constituents of the molten salt FLiBe. Tritium is a unique radionuclide as it readily permeates through hot structural materials. Thus, any material in contact with tritium laden molten salt is a potential pathway for release. Understanding tritium transport and devising adequate control strategies is necessary for the safe operation of MSRs. The Molten Salt Tritium Transport Experiment (MSTTE) is a forced-convection fluoride salt loop with the capability to inject hydrogen isotopes into flowing molten salt and to measure transport phenomena such as permeation through metals and evolution from free-surfaces. MSTTE is designed to be versatile to test potential control technology in future campaigns. This report focuses on the current design and analysis of MSTTE. Custom designed and fabricated experiment components such as the hydrogen injection system, permeation test section, diagnostics, and gas distribution system are discussed in detail. System-level tritium transport modeling using the System Analysis Module investigates experiment parameters such as hydrogen source terms, salt flow rate, and salt temperature. Computational fluid dynamics of the salt flow in the permeation test section informs design choices to establish fully developed flow in the measured permeation zone.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1988

Development of an integrated BEM for hot fluid-structure interaction

One of the most difficult problems in engine structural component durability analysis is the determination of the temperatures and fluxes in the structural components directly in contact with the hot gas flow path. Currently there exists no rational analytical or numerical technique which can effectively deal with this problem. Since the temperature distribution in the structural components are strongly influenced by both the fluid flow and the deformation as well as the cooling system in the structure, the only effective way to deal with this problem is to develop an integrated solid mechanics, fluid mechanics and heat transfer analysis for this problem. Herein, the Boundary Element Method (BEM) is chosen as the basic analysis tool principally because the definition of quantities like fluxes, temperatures, displacements, and velocities are very precise on a boundary based discretization scheme. One fundamental difficulty is that a BEM analysis requires a considerable amount of analytical work which is not present in other numerical methods. During the past year, all of this analytical work was completed and a two dimensional, general purpose code was written. A portion of the work is summarized.

Dargush, G. F.↗
DOE OSTI2021

Droplet Evaporation on Hot Micro-Structured Superhydrophobic Surfaces: Analysis of Evaporation from Droplet Cap and Base Surfaces

In this study, evaporation of sessile water droplets on hot micro-structured superhydrophobic surfaces is experimentally and theoretically investigated. Water droplets of 4 µL are placed on micro-pillared silicon substrates with the substrate temperature heated up to 120°C. A comprehensive thermal circuit model is developed to analyze the effects of substrate roughness and substrate temperature on the sessile droplet evaporation. For the first time, two components of heat and mass transfer, i.e., one from the droplet cap surface and the other from the droplet base surface, during droplet evaporation are distinguished and systematically studied. As such, the evaporation heat transfer rates from both the droplet cap surface and the interstitial liquid-vapor interface between micropillars at the droplet base are calculated in various conditions. For droplet evaporation on the heated substrates in the range of 40°C – 80°C, the predicted droplet cap temperature matches well with the experimental results. Furthermore, during the constant contact radius mode of droplet evaporation, the decrease of evaporation rate from the droplet base contributes most to the continuously decreasing overall evaporation heat transfer rate, whereas the decrease of evaporation rate from the droplet cap surface is dominant in the constant contact angle mode. The influence of internal fluid flow is considered for droplet evaporation on substrates heated above 100°C, and an effective thermal conductivity is adopted as a correction factor to account for the effect of convection heat transfer inside the droplet. Temperature differences between the droplet base and the substrate base are estimated to be about 2°C, 5°C, 8°C, 13°C and 18°C for droplet evaporation on substrates heated at 40°C, 60°C, 80°C, 100°C, and 120°C, respectively, elucidating the delayed or depressed boiling of water droplets on a heated rough surface due to evaporative cooling.

42 ENGINEERING↗
DOE OSTI2024

Structure Factors for Hot Neutron Matter from Ab Initio Lattice Simulations with High-Fidelity Chiral Interactions

We present the first ab initio lattice calculations of spin and density correlations in hot neutron matter using high-fidelity interactions at next-to-next-to-next-to-leading order in chiral effective field theory. These correlations have a large impact on neutrino heating and shock revival in core-collapse supernovae and are encapsulated in functions called structure factors. Unfortunately, calculations of structure factors using high-fidelity chiral interactions were well out of reach using existing computational methods. In this Letter, we solve the problem using a computational approach called the rank-one operator (RO) method. The RO method is a general technique with broad applications to simulations of fermionic many-body systems. It solves the problem of exponential scaling of computational effort when using perturbation theory for higher-body operators and higher-order corrections. Using the RO method, we compute the vector and axial static structure factors for hot neutron matter as a function of temperature and density. Here, the ab initio lattice results are in good agreement with virial expansion calculations at low densities but are more reliable at higher densities. Random phase approximation codes used to estimate neutrino opacity in core-collapse supernovae simulations can now be calibrated with ab initio lattice calculations.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
NASA NTRS1987

Development of an integrated BEM (Boundary Element Mesh) for hot fluid-structure interaction

A boundary integral representation for a coupled approach to fluid flow and solid deformation problems associated with the design of hot-section components such as those in the Space Shuttle Main Engine is discussed. The formulation is based on the fundamental analytical solution of the Navier-Stokes equation for fluid velocity in an infinite domain. This fundamental solution was obtained by decomposing a Navier-Stokes equation into vorticity and dilation transport equations. A boundary integral involving convolutions in time was then constructed in which the convective terms appear in the volume integral.

Dargush, G. F.↗
DOE OSTI2021

The critical role of hot carrier cooling in optically excited structural transitions

The hot carrier cooling occurs in most photoexcitation-induced phase transitions (PIPTs), but its role has often been neglected in many theoretical simulations as well as in proposed mechanisms. Here, by including the previously ignored hot carrier cooling in real-time time-dependent density functional theory (rt-TDDFT) simulations, we investigated the role of hot carrier cooling in PIPTs. Taking IrTe2 as an example, we reveal that the cooling of hot electrons from the higher energy levels of spatially extended states to the lower energy levels of the localized Ir–Ir dimer antibonding states strengthens remarkably the atomic driving forces and enhances atomic kinetic energy. These two factors combine to dissolute the Ir–Ir dimers on a timescale near the limit of atomic motions, thus initiating a deterministic kinetic phase transition. We further demonstrate that the subsequent cooling induces nonradiative recombination of photoexcited electrons and holes, leading to the ultrafast recovery of the Ir–Ir dimers observed experimentally. These findings provide a complete picture of the atomic dynamics in optically excited structural phase transitions.

36 MATERIALS SCIENCE↗
NASA NTRS1985

Einstein observations of the Vela supernova remnant - The spatial structure of the hot emitting gas

Spatially resolved (aproximately 1 arcmin) X-ray maps of the Vela supernova remnant have been constructed in two spectral bands, 0.2-1.0 keV and 0.8-2.0 keV, from a series of 36 separate observations with the Imaging Proportional Counter of the Einstein Observatory. The maps exhibit substantial structure on all angular scales. Spectral analysis shows that the emission from the remnant can be consistently described as thermal radiation from hot gas which is nonuniform in density and temperature, but which is in approximate pressure equilibrium. It is found that p/k is approximately 3-4 x 10 to the 5th/cu cm K. The soft X-ray emission exhibits a high degree of correlation with the optical filamentary structure, in the sense that the most prominent filaments either tightly surround or are coincident with the brightest X-ray regions. This suggests that the softest X-radiation may originate in 'warm' gas which is evaporated from the denser clouds responsible for the optical and ultraviolet filaments. Such an interpretation is quantitatively investigated, and shown to be only marginally consistent with the observations.

Kahn, S. M.↗
NASA NTRS1984

Simplified analytical procedures for representing material cyclic response

Requirements for increased durability of gas turbine hot section structural components have made it necessary to place greater emphasis on accurate structural analysis and life prediction. Linear finite-element analysis is generally sufficient for structural analysis applications. However, for structures in the hot part of the engine, nonlinear structural analysis may be required under certain conditions for the accurate prediction of the local stress-strain response. Nonlinear finite element analysis represents a costly effort which is generally incompatible with the iterative nature of the design process. The present investigation is, therefore, concerned with two simplified procedures for estimating the local hysteretic response produced by cyclic thermal loading. These procedures reduce the need for nonlinear finite-element analysis.

Moreno, V.↗
NASA NTRS1989

Development of an integrated BEM for hot fluid-structure interaction

The Boundary Element Method (BEM) is chosen as a basic analysis tool principally because the definition of quantities like fluxes, temperature, displacements, and velocities is very precise on a boundary base discretization scheme. One fundamental difficulty is, of course, that the entire analysis requires a very considerable amount of analytical work which is not present in other numerical methods. During the last 18 months all of this analytical work was completed and a two-dimensional, general purpose code was written. Some of the early results are described. It is anticipated that within the next two to three months almost all two-dimensional idealizations will be examined. It should be noted that the analytical work for the three-dimensional case has also been done and numerical implementation will begin next year.

Banerjee, P. K.↗
NASA NTRS1989

Probabilistic structural analysis: Introductory remarks

The development of probabilistic structural analysis methodology consists of the following program elements: (1) composite load spectra models, (2) computational probabilistic structural analysis methods, and (3) probabilistic constitutive relationships. The development of the probabilistic structural analysis methodology is a joint program of NASA Lewis in-house and sponsored research. The objective of this session is to illustrate recent progress on the application of this methodology to determine the reliability of structural components for rocket propulsion systems. The session contains descriptions of and progress reports on the following specific activities: (1) The NESSUS computer code, (2) approximate methods, (3) advanced methods, (4) composite load spectra applications, (5) probabilistic fracture mechanisms, and (6) probability of failure and risk analysis. Collectively, the progress to date demonstrates that the structural durability of hot engine structural components can be effectively evaluated in a formal probabilistic/reliability framework.

Chamis, Christos C.↗
NASA NTRS1992

Topology of large-scale structure in seeded hot dark matter models

The topology of the isodensity surfaces in seeded hot dark matter models, in which static seed masses provide the density perturbations in a universe dominated by massive neutrinos is examined. When smoothed with a Gaussian window, the linear initial conditions in these models show no trace of non-Gaussian behavior for r0 equal to or greater than 5 Mpc (h = 1/2), except for very low seed densities, which show a shift toward isolated peaks. An approximate analytic expression is given for the genus curve expected in linear density fields from randomly distributed seed masses. The evolved models have a Gaussian topology for r0 = 10 Mpc, but show a shift toward a cellular topology with r0 = 5 Mpc; Gaussian models with an identical power spectrum show the same behavior.

Beaky, Matthew M.↗
NASA NTRS2001

Lightweight Structures

Present structural concepts for hot static structures are conventional "sheet & stringer" or truss core construction. More weight-efficient concepts such as honeycomb and lattice block are being investigated, in combination with both conventional superalloys and TiAl. Development efforts for components made from TiAl sheet are centered on lower cost methods for sheet and foil production, plus alloy development for higher temperature capability. A low-cost casting technology recently developed for aluminum and steel lattice blocks has demonstrated the required higher strength and stiffness, with weight efficiency approach- ing honeycombs. The current effort is based on extending the temperature capability by developing lattice block materials made from IN-718 and Mar-M247.

Whittenberger, J. Daniel↗
NASA NTRS1988

Structural analysis methods development for turbine hot section components

The structural analysis technologies and activities of the NASA Lewis Research Center's gas turbine engine Hot Section Technology (HOST) Program are summarized. The technologies synergistically developed and validated include: time-varying thermal/mechanical load models; component-specific automated geometric modeling and solution strategy capabilities; advanced inelastic analysis methods; inelastic constitutive models; high-temperature experimental techniques and experiments; and nonlinear structural analysis codes. Features of the program that incorporate the new technologies and their application to hot section component analysis and design are described. Improved and, in some cases, first-time 3-D nonlinear structural analyses of hot section components of isotropic and anisotropic nickel-base superalloys are presented.

Thompson, R. L.↗
NASA NTRS1997

Post-flare loops embedded in a hot coronal fan-like structure

Limb events were demonstrated on the sun in which rising post-flare loops were embedded in hot structures looking in soft X-rays like fans of rays, formed during the flare and extending high into the corona. One of these structures is analyzed and it is suggested that these fans of rays represent temporary ministreamers, along which mass flows into interplanetary space. This suggestion is supported by maps of solar wind density constructed from scintillation measurements.

Svestka, Z.↗