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NASA NTRS2002

Oxidation and Volatilization of Silica-Formers in Water Vapor

At high temperatures SiC and Si3N4 react with water vapor to form a silica scale. Silica scales also react with water vapor to form a volatile Si(OH)4 species. These simultaneous reactions, one forming silica and the other removing silica, are described by paralinear kinetics. A steady state, in which these reactions occur at the same rate, is eventually achieved, After steady state is achieved, the oxide found on the surface is a constant thickness and recession of the underlying material occurs at a linear rate. The steady state oxide thickness, the time to achieve steady state, and the steady state recession rate can all be described in terms of the rate constants for the oxidation and volatilization reactions. In addition, the oxide thickness, the time to achieve steady state, and the recession rate can also be determined from parameters that describe a water vapor-containing environment. Accordingly, maps have been developed to show these steady state conditions as a function of reaction rate constants, pressure, and gas velocity. These maps can be used to predict the behavior of silica formers in water-vapor containing environments such as combustion environments. Finally, these maps are used to explore the limits of the paralinear oxidation model for SiC and Si3N4

Opila, E. J.↗

NASA NTRS2002

Graphite Ablation and Thermal Response Simulation Under Arc-Jet Flow Conditions

The Two-dimensional Implicit Thermal Response and Ablation program, TITAN, was developed and integrated with a Navier-Stokes solver, GIANTS, for multidimensional ablation and shape change simulation of thermal protection systems in hypersonic flow environments. The governing equations in both codes are demoralized using the same finite-volume approximation with a general body-fitted coordinate system. Time-dependent solutions are achieved by an implicit time marching technique using Gauess-Siedel line relaxation with alternating sweeps. As the first part of a code validation study, this paper compares TITAN-GIANTS predictions with thermal response and recession data obtained from arc-jet tests recently conducted in the Interaction Heating Facility (IHF) at NASA Ames Research Center. The test models are graphite sphere-cones. Graphite was selected as a test material to minimize the uncertainties from material properties. Recession and thermal response data were obtained from two separate arc-jet test series. The first series was at a heat flux where graphite ablation is mainly due to sublimation, and the second series was at a relatively low heat flux where recession is the result of diffusion-controlled oxidation. Ablation and thermal response solutions for both sets of conditions, as calculated by TITAN-GIANTS, are presented and discussed in detail. Predicted shape change and temperature histories generally agree well with the data obtained from the arc-jet tests.

Chen, Y.-K.↗

NASA NTRS2005

Performance of a Light-Weight Ablative Thermal Protection Material for the Stardust Mission Sample Return Capsule

New tests and analyses are reported that were carried out to resolve testing uncertainties in the original development and qualification of a lightweight ablative material used for the Stardust spacecraft forebody heat shield. These additional arcjet tests and analyses confirmed the ablative and thermal performance of low density Phenolic Impregnated Carbon Ablator (PICA) material used for the Stardust design. Testing was done under conditions that simulate the peak convective heating conditions (1200 W/cm2 and 0.5 atm) expected during Earth entry of the Stardust Sample Return Capsule. Test data and predictions from an ablative material response computer code for the in-depth temperatures were compared to guide iterative adjustment of material thermophysical properties used in the code so that the measured and predicted temperatures agreed. The PICA recession rates and maximum internal temperatures were satisfactorily predicted by the computer code with the revised properties. Predicted recession rates were also in acceptable agreement with measured rates for heating conditions 37% greater than the nominal peak heating rate of 1200 W/sq cm. The measured in-depth temperature response data show consistent temperature rise deviations that may be caused by an undocumented endothermic process within the PICA material that is not accurately modeled by the computer code. Predictions of the Stardust heat shield performance based on the present evaluation provide evidence that the maximum adhesive bondline temperature will be much lower than the maximum allowable of 250 C and an earlier design prediction. The re-evaluation also suggests that even with a 25 percent increase in peak heating rates, the total recession of the heat shield would be a small fraction of the as-designed thickness. These results give confidence in the Stardust heat shield design and confirm the potential of PICA material for use in new planetary probe and sample return applications.

Covington, M. A.↗

NASA NTRS1988

Orbital maneuvering vehicle end effectors

An end effector device (A) for grasping and holding an article such as a handle (18) of a space telescope is disclosed. The device includes a V-shaped capture window (74) defined as inclined surfaces (76, 78) in parallel face plates (22, 24) which converge toward a retainer recess (54) in which the handle is retained. A pivotal finger (30) meshes with a pair of pivoted fingers (26, 28) which rotate in counterrotation. The fingers rotate to pull a handle within the capture window into recess (54) where latches (50) lock handle (18) in the recess. To align the capture window, plates (22, 24) may be cocked plus or minus five degrees on base (64).

Myers, W. Neill↗

NASA NTRS1987

Labyrinthine turbine-rotor-blade tip seal

Means for sealing the tip 18 of a rotor turbine blade 10 against tip leakage flow comprising a multiplicity of recesses 30 formed in the surface of the tip 18. The recesses 30 are preferably formed in a labyrinthine or slaggered pattern which interposes at least one recess 30 in every leakage flow path across the tip 18 from the pressure side 26 to the suction side 28 of the blade 10.

Wagner, William R.↗

NASA NTRS1989

Hanging drop crystal growth apparatus and method

An apparatus (10) is constructed having a cylindrical enclosure (16) within which a disc-shaped wicking element (18) is positioned. A well or recess (22) is cut into an upper side (24) of this wicking element, and a glass cover plate or slip (28) having a protein drop disposed thereon is sealably positioned on the wicking element (18), with drop (12) being positioned over well or recess (22). A flow of control fluid is generated by a programmable gradient former (16), with this control fluid having a vapor pressure that is selectively variable. This flow of control fluid is coupled to the wicking element (18) where control fluid vapor diffusing from walls (26) of the recess (22) is exposed to the drop (12), forming a vapor pressure gradient between the drop (12) and the control fluid vapor. Initially, this gradient is adjusted to draw solvent from the drop (12) at a relatively high rate, and as the critical supersaturation point is approached (the point at which crystal nucleation occurs), the gradient is reduced to more slowly draw solvent from the drop (12). This allows discrete protein molecules more time to orient themselves into an ordered crystalline lattice, producing protein crystals which, when processed by X-ray crystallography, possess a high degree of resolution.

Carter, Daniel C.↗

NASA NTRS2008

Modeling of the Ablation of Fibrous Materials in the Knudsen Regime

During atmospheric entry of planetary probes, the thermal protection system (TPS) of the probe is exposed to high temperatures under low pressures. In these conditions, carbonous TPS materials undergo gasification in the Knudsen regime leading to mass loss and wall recession called ablation. This work aims to improve the understanding of materiaVenvironment interactions through a study of the coupling between carbon dioxide transport in the Knudsen regime, heterogeneous oxidation of carbon, and sutface recession. A 3D Monte-Carlo simulation tool is used for this study. The fibrous architecture of the materiils, consisting of high porosity random array of carbon fibers, is numerically reproduced on a 3D Cartesian grid. Mass transport in the Knudsen regime from the boundary layer to the surface, and inside this porous material is simulated by random walk. A reaction probability is used to simulate the heterogeneous oxidation reaction. The surface recession is followed by front tracking using a simplified marching cube approach. The output data of the simulations are ablation velocity and dynamic evolution of the material porosity. A parametric study is carried out to analyze the material behavior as a function of Knudsen number for the porous media (length of the mean free path compared to the mean pore diameter) and the intrinsic reactivity of the carbon fibers. The results enable extrapolation of laboratory experimental data to actual entry conditions.

Lachaud, J.↗

NASA NTRS2009

Validation of PICA Ablation and Thermal-Response Model at Low Heat Flux

Phenolic Impregnated Carbon Ablator (PICA) was the forebody heatshield material on the Stardust sample-return capsule and is also a primary candidate material for the Mars Science Lander (MSL), the Orion Crew Module, and the SpaceX Dragon vehicle. As part of the heatshield qualification for Orion, physical and thermal properties of virgin and charred PICA were measured, and an ablation and thermal response model was developed. We validated the model by comparing it with recession and temperature data from stagnation arcjet tests conducted over a wide range of stagnation heat flux of 107 to 1102 W/sq cm. The effect of orthotropic thermal conductivity was evident in the thermal response of the arcjet models. In general, model predictions compared well with the data; however, the uncertainty of the recession prediction was greatest for heat fluxes below 200 W/sq cm. More recent MSL testing focused on the low heat flux regime of 45 to 250 W/sq cm. The new results confirm the recession uncertainty, especially for pressures below 6 kPa. In this work we focus on improving the model predictions for MSL and Orion tests below 250 W/sq cm.

Milos, Frank S.↗

NASA NTRS2008

Multiscale Modeling of Ablation and Pyrolysis in PICA-Like materials

During atmospheric entry of planetary probes, the thermal protection system (TIPS) of the probe is exposed to high temperatures under low pressures. In these conditions, carbonous fibrous TIPS materials may undergo oxidation leading to mass loss and wall recession called ablation. This work aims to improve the understanding of material/environment interactions through a study of the coupling between oxygen transport in the Knudsen regime, heterogeneous oxidation of carbon, and surface recession. A 3D Random Walk Monte Carlo simulation tool is used for this study. The fibrous architecture of a model material, consisting of high porosity random array of carbon fibers, is numerically represented on a 3D Cartesian grid. Mass transport in the Knudsen regime from the boundary layer to the surface, and inside this porous material is simulated by random walk. A reaction probability is used to simulate the heterogeneous oxidation reaction. The surface recession of the fibers is followed by front tracking using a simplified marching cube approach. The output data of the simulations are ablation velocity and dynamic evolution of the material porosity. A parametric study is carried out to analyze the material behavior as a function of Knudsen number for the porous media (length of the mean free path compared to the mean pore diameter) and the intrinsic reactivity of the carbon fibers. The model is applied to Stardust mission reentry conditions and explains the unexpected behavior of the TIPS material that underwent mass loss in volume.

Lachaud, Jean↗

NASA NTRS2011

Anti-Rotation Device Releasable by Insertion of a Tool

A drive mechanism enables a socket-type wrench to rotate a shaft and prevents accidental rotation of the shaft when the wrench is not coupled to the shaft. In the original intended application, the shaft would be part of an attachment mechanism on a spacecraft, and the purpose to be served by the drive is to prevent back-driving of the shaft by launch vibrations while enabling an astronaut equipped with the appropriate wrench to actuate the shaft while in orbit. The design could also be adapted to terrestrial applications in which it is necessary to prevent rotational back-driving. The mechanism includes a gear near the tip of the shaft, and a drive nut that constitutes the tip of the shaft. The gear and drive nut are positioned in a recess in a housing. The recess is sized to receive the wrench socket that mates with the drive nut. Also contained in the housing are four linkages that include pins that are spring-loaded into engagement with the gear to prevent rotation of the shaft. When the wrench socket is inserted in the recess, it pushes on the linkages in such a manner as to disengage the pins from the gear.

Warden, Harry K.↗

NASA NTRS2012

Linear and/or curvilinear rail mount system

One or more linear and/or curvilinear mounting rails are coupled to a structure. Each mounting rail defines a channel and at least one cartridge assembly is engaged in the channel. Each cartridge assembly includes a housing that slides within the channel. The housing defines a curvilinearly-shaped recess longitudinally aligned with the channel when the housing is in engagement therewith. The cartridge assembly also includes a cleat fitted in the recess for sliding engagement therealong. The cleat can be coupled to a fastener that passes through the mounting rail and the housing when the housing is so-engaged in the channel. The cleat is positioned in the recess by a position of the fastener.

Thomas, Jackie D.↗

NASA NTRS2013

High-Reliability Waveguide Vacuum/Pressure Window

The NASA Deep Space Network (DSN) uses commercial waveguide windows on the output waveguide of Ka-band (32 GHz) low-noise amplifiers. Mechanical failure of these windows resulted in an unacceptable loss in tracking time. To address this issue, a new Ka-band WR-28 waveguide window has been designed, fabricated, and tested. The window uses a slab of low-loss, low-dielectric constant foam that is bonded into a 1/2-wave-thick waveguide/flange. The foam is a commercially available, rigid, closed-cell polymethacrylimide. It has excellent electrical properties with a dielectric constant of 1.04, and a loss tangent of 0.01. It is relatively strong with a tensile strength of 1 MPa. The material is virtually impermeable to helium. The finished window exhibits a leak rate of less than 3x10(exp -3)cu cm/s with helium. The material is also chemically resistant and can be cleaned with acetone. The window is constructed by fabricating a window body by brazing a short length of WR-28 copper waveguide into a standard rectangular flange, and machining the resulting part to a thickness of 4.6 mm. The foam is machined to a rectangular shape with a dimension of 7.06x3.53 mm. The foam is bonded into the body with a two-part epoxy. After curing, the excess glue and foam are knife-trimmed by hand. The finished window has a loss of less than 0.08 dB (2%) and a return loss of greater than 25 dB at 32 GHz. This meets the requirements for the DSN application. The window is usable for most applications over the entire 26-to-40-GHz waveguide band. The window return loss can be tuned to a required frequency by var y in g the thickness of the window slightly. Most standard waveguide windows use a thin membrane of material bonded into a recess in a waveguide flange, or sandwiched between two flanges with a polymer seal. Designs using the recessed window are prone to mechanical failure over time due to constraints on the dimensions of the recess that allow the bond to fail. Designs using the sandwich method are often permeable to helium, which prohibits the use of helium leak detection. At the time of this reporting, 40 windows have been produced. Twelve are in operation with a combined operating time of over 30,000 hours without a failure.

Britcliffe, Michael J.↗

NASA NTRS2015

Evaluation of Finite-Rate Gas/Surface Interaction Models for a Carbon Based Ablator

Two sets of finite-rate gas-surface interaction model between air and the carbon surface are studied. The first set is an engineering model with one-way chemical reactions, and the second set is a more detailed model with two-way chemical reactions. These two proposed models intend to cover the carbon surface ablation conditions including the low temperature rate-controlled oxidation, the mid-temperature diffusion-controlled oxidation, and the high temperature sublimation. The prediction of carbon surface recession is achieved by coupling a material thermal response code and a Navier-Stokes flow code. The material thermal response code used in this study is the Two-dimensional Implicit Thermal-response and Ablation Program, which predicts charring material thermal response and shape change on hypersonic space vehicles. The flow code solves the reacting full Navier-Stokes equations using Data Parallel Line Relaxation method. Recession analyses of stagnation tests conducted in NASA Ames Research Center arc-jet facilities with heat fluxes ranging from 45 to 1100 wcm2 are performed and compared with data for model validation. The ablating material used in these arc-jet tests is Phenolic Impregnated Carbon Ablator. Additionally, computational predictions of surface recession and shape change are in good agreement with measurement for arc-jet conditions of Small Probe Reentry Investigation for Thermal Protection System Engineering.

Ablation↗

NASA NTRS2017

Shallow Lunar Seismic Activity and the Current Stress State of the Moon

A vast, global network of more than 3200 lobate thrust fault scarps has been revealed in high resolution Lunar Reconnaissance Orbiter Camera (LROC) images. The fault scarps very young, less than 50 Ma, based on their small scale and crisp appearance, crosscutting relations with small-diameter impact craters, and rates of infilling of associated small, shallow graben and may be actively forming today. The population of young thrust fault scarps provides a window into the recent stress state of the Moon and offers insight into the origin of global lunar stresses. The distribution of orientations of the fault scarps is non-random, inconsistent with isotropic stresses from late-stage global contraction as the sole source of stress Modeling shows that tidal stresses contribute significantly to the current stress state of the lunar crust. Tidal stresses (orbital recession and diurnal tides) superimposed on stresses from global contraction result in non-isotropic compressional stress and thrust faults consistent with lobate scarp orientations. Stresses due to orbital recession do not change with orbital position, thus it is with the addition of diurnal stresses that peak stresses are reached. At apogee, diurnal and recession stresses are most compressive near the tidal axis, while at perigee they are most compressive 90 degrees away from the tidal axis. Coseismic slip events on currently active thrust faults are expected to be triggered when peak stresses are reached. Analysis of the timing of the 28 the shallow moonquakes recorded by the Apollo seismic network shows that 19 indeed occur when the Moon is closer to apogee, while only 9 shallow events occur when the Moon is closer to perigee. Here we show the results of relocating the shallow moonquake using an algorithm designed for sparse networks to better constrain their epicentral locations in order to compare them with stress models. The model for the current stress state of the Moon is refined by investigating the contribution of polar wander.

siesmology↗

NASA NTRS2018

Shrouded CMC Rotor Blades for High Pressure Turbine Applications

The density of Ceramic Matrix Compos-ite(CMC) materials is approximately 1/3 the density of metals currently used for High Pressure Turbine(HPT) blades. A lower density, and consequently lower centrifugal stresses, increases the feasibility of shrouding HPT blades. Shrouding HPT blades improves aerodynamic eciency, especially for low aspect ratio turbine blades. This paper explores aerodynamic and structural issues associated with shrouding HPT rotor blades. Detailed Navier-Stokes analysis of a rotor blade showed that shrouding improved blade row aerodynamic eciency by 1.3%, when the clearance was 2% of the blade span. Recessed casings were used. Without a shroud the depth of the recess equaled the clearance. With a shroud the recess depth increased by the shroud thickness, which included a knife seal. There was good agreement between the predicted stage eciency for the unshrouded blades and the experimentally measured efficiency. Structural analysis showed a strong interaction between stresses in the shroud and peak stresses at the hub of the blade. A thin shroud of uniform thickness only moderately increased maximum blade stress, but there were very high stresses in the shroud itself. Increasing shroud thickness reduced stresses in the shroud, but increased blade stresses near the hub. A single knife seal added to the thin shroud noticeably decreased maximum shroud stress, without increasing maximum blade stress. Maximum stresses due to pressure loads and combined pressure and centrifugal loads were nearly the same as the maximum stresses for individual pressure or cen-trifugal loads. Stresses due to a 100K temperature

Ceramic Matrix Composite↗

NASA NTRS2018

Significance of DSMC Computed Aerothermal Environments in the Rarefied Regime for Atmospheric Entry Material Response

During Mars atmospheric entry, the Mars Science Laboratory (MSL) was protected by a 4.5 meters diameter ablative heatshield assembled in 113 tiles. The heatshield was made of NASA's flagship ablative material, the Phenolic Impregnated Carbon Ablator (PICA). Prior work compared the traditional one-dimensional and three-dimensional material response models at different locations in the heatshield. It was observed that the flow was basically one-dimensional in the nose and flank regions, but three-dimensional flow effects were observed in the outer flank. The objective of this work is to study the effects of the aerothermal environment on the material response. We extend prior work by computing aerothermal environments using the direct simulation Monte Carlo (DSMC) code SPARTA and the CFD code Data Parallel Line Relaxation (DPLR). SPARTA is used to compute environment in the rarefied regime prior to 48.4s of entry where the Knudsen number is such that the Navier-Stokes equations can be inaccurate. Similarly to previous work, the DPLR software is used to compute the hypersonic environment for laminar then turbulent boundary layer assumptions from 48.4 s up to 100 s after Entry Interface (EI) along the MSL 08-TPS-02/01a trajectory. We observe that extending the aerothermal environments to times prior to 48.4 s modifies the thermal response of the heat shield at the surface and in-depth; however the effects on the recession are minimal. Additionally, using the assumption of a turbulent boundary layer versus a laminar one leads to higher surface and in-depth temperatures, larger recession, and a displacement of the peak heating and peak recession location.

Aerothermal↗

NASA NTRSDate not supplied

MEDLI2: Ablator Models for Flight

During the entry of Mars Science Laboratory (MSL) the heatshield was equipped with the instrumentation suite Mars Entry, Descent, and Landing Instruments (MEDLI). In-depth thermocouple (TC) data was used to reconstruct the surface heating[1,2]. Discrepancies between MEDLI’s flight heating data and predicted thermal response and recession[3] led to a campaign to characterize and test Mars2020 and MEDLI2 (Mars Entry, Descent, and Landing Instrument 2)[4] flight-lot thermal protection materials (TPS) at relevant ground test conditions. This paper covers the development and validation of flight-lot material response models for the heatshield material Phenolic Impregnated Carbon Ablator (PICA) and the backshell material SLA-561V (Super Lightweight Ablator). Virgin and char properties such as thermal conductivity and emissivity were updated as a function of temperature and pressure in the MEDLI2 specific material response models. Other material properties were characterized and determined to be similar to prior TPS material measurements used for the heritage models. MEDLI2 also investigated the impact of the protective coating that was applied to MSL and Mars2020’s PICA heatshield to reduce the particulate matter shedding. Evidence from arc jet experiments on coated PICA showed that although there were no adverse effects on the performance of the TPS, there were differences in the in-depth temperatures and reduced recession compared to material response predictions of uncoated PICA.[5,6]. Fully Implicit Ablation and Thermal response (FIAT)[7] material response simulations were conducted with the heritage and MEDLI2 flight-lot material models. FIAT-predicted in-depth temperature responses and recession predictions were compared to flight-lot certification ground-test arc jet test data and MEDLI2 thermocouple data.

Materials Response↗

NASA NTRSDate not supplied

Computation of Effective Mechanical Properties and Mechanical Erosion Modeling of TPS Materials

The goal of this presentation is to provide a general overview of the multi-scale modeling formulation to determine if there is additional surface recession in Thermal Protection Systems (TPS) materials as a result of mechanical erosion due to high shear conditions during atmospheric entry. This modeling process is performed at different scales by leveraging two computational frameworks developed at NASA: the Porous Microstructure Analysis (PuMA) software, and the Porous material Analysis Toolbox based on OpenFOAM (PATO). PuMA specializes in computing effective macro-scale material properties by performing material response simulations on 3D digital micro-scale representations of porous micro-structures. The modeling of TPS materials at the micro-scale is essential to understand how they behave as part of a heat shield assembly. The first part of the presentation will detail the implementation of PuMA’s cell-centered finite volume elasticity solver, which allows the computation of macro-scale effective mechanical properties of heterogeneous and anisotropic materials such as fibrous and woven TPS composites. These homogenized mechanical properties are used by PATO’s mechanical erosion model to predict the TPS material’s recession at a larger scale. This work will also provide some examples of multi-scale analysis from the fiber level up to the unit cell. The second part of the presentation will focus on the macro-scale approach to determine if erosion at the heat shield’s surface occurs due to mechanical and thermal loads experienced during atmospheric entry. To accomplish this, a solid mechanics module was integrated within PATO enabling it to model the potential mechanical erosion in three steps: first, after obtaining the effective mechanical properties with PuMA, the implemented stress analysis solver computes the stress and the displacement fields for the TPS material using the wall shear stress tensor, computed using a CFD solver, as boundary conditions; then, regions on the surface where the stress meets the failure criteria are identified; finally, the failed material is removed and the mesh is redistributed accordingly. The outcome is a model capable of predicting the total recession in the material due to surface chemistry and mechanical erosion.

Mechanical Properties↗