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NASA NTRS2013

CFD Script for Rapid TPS Damage Assessment

This grid generation script creates unstructured CFD grids for rapid thermal protection system (TPS) damage aeroheating assessments. The existing manual solution is cumbersome, open to errors, and slow. The invention takes a large-scale geometry grid and its large-scale CFD solution, and creates a unstructured patch grid that models the TPS damage. The flow field boundary condition for the patch grid is then interpolated from the large-scale CFD solution. It speeds up the generation of CFD grids and solutions in the modeling of TPS damages and their aeroheating assessment. This process was successfully utilized during STS-134.

McCloud, Peter↗

NASA NTRS1995

Thermal Stress Analysis of RCG-Tempered TUFI Tile TPS for Hypersonic Vehicles

This paper presents detailed results from linear and nonlinear finite-element thermal stress analyses of a new tile, Thermal Protection Systems (TPS) concept. A very thin coating of Reaction Cured Glass (RCG) is used to "temper" the surface of Toughened Uni-Piece Fibrous Insulation (TUFI) tiles to improve resistance to thermal shock and thermal cycling effects. The coating also serves to reduce catalytic heating and may improve waterproofing. Calculations include trajectory-based aerothermal heating environments for X-34 wing leading edge TPS designs and arc jet environments for TPS test articles. The nonlinear analyses include the high temperature plasticity of RCG to demonstrate the reuseability of the material.

Milos, Frank S.↗

NASA NTRS2010

Development of Thermal Protection Materials for Future Mars Entry, Descent and Landing Systems

Entry Systems will play a crucial role as NASA develops the technologies required for Human Mars Exploration. The Exploration Technology Development Program Office established the Entry, Descent and Landing (EDL) Technology Development Project to develop Thermal Protection System (TPS) materials for insertion into future Mars Entry Systems. An assessment of current entry system technologies identified significant opportunity to improve the current state of the art in thermal protection materials in order to enable landing of heavy mass (40 mT) payloads. To accomplish this goal, the EDL Project has outlined a framework to define, develop and model the thermal protection system material concepts required to allow for the human exploration of Mars via aerocapture followed by entry. Two primary classes of ablative materials are being developed: rigid and flexible. The rigid ablatives will be applied to the acreage of a 10x30 m rigid mid L/D Aeroshell to endure the dual pulse heating (peak approx.500 W/sq cm). Likewise, flexible ablative materials are being developed for 20-30 m diameter deployable aerodynamic decelerator entry systems that could endure dual pulse heating (peak aprrox.120 W/sq cm). A technology Roadmap is presented that will be used for facilitating the maturation of both the rigid and flexible ablative materials through application of decision metrics (requirements, key performance parameters, TRL definitions, and evaluation criteria) used to assess and advance the various candidate TPS material technologies.

Cassell, Alan M.↗

NASA NTRS1979

SRB TPS closeout materials characterization

The recession characteristics of the materials used to closeout the Thermal Protection System (TPS) on the Space Shuttle Solid Rocket Booster (SRB) were assessed. Two candidate closeout materials namely, K5NA and MTA2 is the Marshall Trowelable Ablator. Test panels of each of these two materials were subjected to aerodynamic heat and shear in the NASA Hot Gas Facility. Pretest and Post-test measurements were taken and the rate of recession (R) thus determined was correlated with the heating rate. A least squares curve fit of the data together with another least squares 95% confidence level fit, was performed. The characteristics of the two materials when compared showed that both materials performed equally well at the higher heating rates (10 q 30 Btu/sq ft/sec) but MTA2 was slightly better, not receding as fast, at the lower q values. The comparison of the R versus q curves for K5NA and MTA2 with that of primary TPS P-50 cork on the SRB Aft Skirt was good.

Karu, Z. S.↗

NASA NTRS2004

TPS: From Arc-Jet to Flight

This slide presentation reviews the testing of thermal protection system materials. All space vehicles that reenter Earth's atmosphere from either LEO or from Lunar/Mars missions require thermal protection system (TPS) materials. These TPS materials requires ground test facilities that simulate the aerothermodynamic environments experienced by reentry. The existing arc-jet facility requires expansion to combine convective and radiation heating and to test the capability to protect with the CO2 atmosphere that will be encountered for Martian entry.

Buslog, Stanley A.↗

NASA NTRS2018

Orion EM-2 TPS Radiometer & Spectrometer

Radiometers and Spectrometers embedded as flight instrumentation in a spacecraft's thermal protection system (TPS) can generate data on shock layer radiation to a spacecraft's surface for high-speed trajectories such as lunar return. Robust and accurate flight measurements of shock layer radiation can validate models and inform TPS selection and sizing, to reduce risk and TPS launch mass. Contamination from soot deposition and ablation products in the boundary layer condensing on a cold sapphire radiometer window or blocking open ports interferes with measurements. This poster describes characterization of the optical properties and performance of relevant materials, components, and contaminated windows, as well as investigation of contamination control strategies for the optics.

Ablation↗

NASA NTRS1982

Analytical and experimental evaluations of Space Shuttle TPS tile vibration response

Analytical studies and laboratory experiments have been performed to evaluate the vibration response of the Space Shuttle Thermal Protection System (TPS) tiles due to the intense rocket generated acoustic noise during lift-off. The TPS tiles are mounted over the exterior of the Space Shuttle Orbiter structure through Strain Isolation Pads (SIP) which protect the tiles from thermal induced shear loads at their interface. The analytical predictions indicate that the response of a typical tile is governed by the structural vibration inputs through the SIP under the tile at frequencies below 250 Hz, and by the direct acoustic excitation over the exterior surface of the tile at frequencies above 250 Hz. An evaluation of the laboratory test data for this same tile, in which conditioned (partial) coherent output spectral analysis procedures were used, leads to exactly the same conclusion. The results demonstrate the power of conditioned spectral analysis procedures in identifying vibration response mechanisms when two or more of the inputs are highly correlated.

Piersol, A. G.↗

NASA NTRS2016

Thermal Testing of Ablators in the NASA Johnson Space Center Radiant Heat Test Facility

A spacecraft's thermal protection system (TPS) is required to survive the harsh environment experienced during reentry. Accurate thermal modeling of the TPS is required to since uncertainties in the thermal response result in higher design margins and an increase in mass. The Radiant Heat Test Facility (RHTF) located at the NASA Johnson Space Center (JSC) replicates the reentry temperatures and pressures on system level full scale TPS test models for the validation of thermal math models. Reusable TPS, i.e. tile or reinforced carbon-carbon (RCC), have been the primary materials tested in the past. However, current capsule designs for MPCV and commercial programs have required the use of an ablator TPS. The RHTF has successfully completed a pathfinder program on avcoat ablator material to demonstrate the feasibility of ablator testing. The test results and corresponding ablation analysis results are presented in this paper.

Del Papa, Steven↗

NASA NTRS1986

Mars vehicle TCS and aerobrake TPS

General design approach, some problems and technology needs for a Mars vehicle manned module Thermal Control System (TCS) and aerobrake Thermal Protection System (TPS) are discussed. The design approach of the TCS will be similar to that of the space station. Mars atmospheric dust storms are identified as an unknown that will impact the design of the Mars landing vehicle and base facility. New technology may be needed for thermal control surfaces to functionally survive the dust storms. The TPS for the Mars aerocapture vehicle will be subject to marginal stagnation heating rates for conjunction class missions and very high heating rates for opposition class missions. New technology TPS materials or an ablative heat shield will be required for the high stagnation heating rate trajectories. No significantly new technology is needed for the manned modules that do not descent to the Mars surface.

Comer, G.↗

NASA NTRSDate not supplied

Thermal Protection Systems for Aerospace Vehicles During Atmospheric Entry

Atmospheric entry and need for thermal protection systems (TPS) is discussed. Ceramic insulations for use as passive TPS are described. Different modes of heat transfer in ceramic insulation are described, and a thermal model is presented. Figures of merit for insulation performance are described and various methods for improving insulation performance are presented.

thermal protection system↗

NASA NTRS2002

Investigation of Fundamental Modeling and Thermal Performance Issues for a Metallic Thermal Protection System Design

A study was performed to develop an understanding of the key factors that govern the performance of metallic thermal protection systems for reusable launch vehicles. A current advanced metallic thermal protection system (TPS) concept was systematically analyzed to discover the most important factors governing the thermal performance of metallic TPS. A large number of relevant factors that influence the thermal analysis and thermal performance of metallic TPS were identified and quantified. Detailed finite element models were developed for predicting the thermal performance of design variations of the advanced metallic TPS concept mounted on a simple, unstiffened structure. The computational models were also used, in an automated iterative procedure, for sizing the metallic TPS to maintain the structure below a specified temperature limit. A statistical sensitivity analysis method, based on orthogonal matrix techniques used in robust design, was used to quantify and rank the relative importance of the various modeling and design factors considered in this study. Results of the study indicate that radiation, even in small gaps between panels, can reduce significantly the thermal performance of metallic TPS, so that gaps should be eliminated by design if possible. Thermal performance was also shown to be sensitive to several analytical assumptions that should be chosen carefully. One of the factors that was found to have the greatest effect on thermal performance is the heat capacity of the underlying structure. Therefore the structure and TPS should be designed concurrently.

Blosser, Max L.↗

NASA NTRSDate not supplied

Mechanical Erosion Modeling of TPS Materials

This work describes the development of a model that accounts for the additional surface recession in Thermal Protection Systems (TPS) materials as a result of mechanical erosion due to high shear conditions during atmospheric entry. A computational solid mechanics module was integrated within the Porous material Analysis Toolbox (PATO) based on OpenFOAM. The mechanical erosion was modeled in three steps: first, the implemented stress analysis solver computes the stress and the displacement fields for orthotropic materials using the wall shear stress tensor as a boundary condition; then, regions on the surface where the stress meets the failure criteria are identified; and last, the mesh is moved accordingly to remove the failed material. The outcome is a model capable to predict the total recession of the material due to surface chemistry and mechanical erosion. Results will be included in the final paper after verifying and completing the study.

Stress Analysis↗

NASA NTRSDate not supplied

Mechanical Erosion Modeling of TPS Materials

Stress Analysis↗

NASA NTRSDate not supplied

NASA's Innovative Entry Systems and TPS Technologies Enabling Commercial Space Missions

For over six decades, the NASA Ames Entry Systems and Technology Division has been a cornerstone of U.S. space exploration, delivering critical atmospheric entry solutions since Project Mercury and now increasingly supporting the commercial space sector. The Division provides reliable entry system solutions through a unique blend of expertise, national facilities, and systems integration knowledge, a combination that is difficult to replicate outside a dedicated government entity. Consistently successful, the TS Division remains central to NASA’s exploration objectives and significantly contributes to the transfer of technology to the commercial space sector, supporting more than ten commercial space companies and supplying flight heatshields to three of them in the past five years. Its strengths in Thermal Protection System (TPS) materials, aerothermodynamics, ground test facilities, and Entry, Descent, and Landing (EDL) systems engineering drive rapid development and sustained U.S. competitiveness in space. The Division's expertise in reusable and ablative thermal protection systems, as well as mechanically deployable entry systems primarily developed for NASA missions, now benefits commercial space missions. This presentation will highlight the vision and needs of these commercial space companies, how NASA-invented technologies meet mission requirements, and how these technologies enable and distinguish their efforts.

Ethiraj Venkatapathy↗

NASA NTRS1979

Use of arc-jet hypersonic blunted wedge flows for evaluating performance of Orbiter TPS

Arc-jet tests at NASA/JSC have been conducted recently to evaluate the performance of the Orbiter Thermal Protection System (TPS) on three critical areas of the side and top of the Orbiter fuselage: (1) cargo bay door, (2) crew access door, and (3) LRSI/FRSI joint regions. Test articles corresponding to these three areas on the Orbiter were mounted in an arc-jet test chamber in a blunted-wedge holder and exposed to hypersonic flow at various angles of attack. The effects of flow direction, heating load, and overtemperature were investigated. In addition, the reuse capability of the TPS materials was evaluated, along with the protection of the pressure seals within the test articles. Thermal match model predictions correlated well with primary structure thermocouple data. Heating rate and pressure predictions based on a nonequilibrium flow field computer program showed good agreement with arc-jet test data and existing hypersonic flow theories.

Rochelle, W. C.↗

NASA NTRS2014

Extending Our Understanding of Compliant Thermal Barrier Performance

Thermal barriers and seals are integral components in the thermal protection systems (TPS) of nearly all aerospace vehicles. They are used to minimize the flow of hot gases through interfaces and protect underlying temperature-sensitive components and systems. Although thermal barriers have been used extensively on many aerospace vehicles, the factors affecting their thermal and mechanical performance are not well-understood. Because of this, vehicle TPS designers are often left with little guidance on how to properly design and optimize these barriers. An ongoing effort to better understand thermal barrier performance and develop models and design tools is in progress at the NASA Glenn Research Center. Testing has been conducted to understand the degree to which insulation density influences structural performance and permeability. In addition, the development of both thermal and mechanical models is ongoing with the goal of providing an improved ability to design and implement these critical TPS components.

high temperature↗

NASA NTRS2020

TPS and Entry Technologies for Future Outer Planet Exploration

The lack of knowledge about the Ice Giants (Voyager being the only probe to briefly visit them) and literally narrow window of planetary alignment for pragmatic missions to the Ice Giants, make them high priority targets in the next decade. The purpose of this white paper is to provide an overview to the NRC Decadal Survey on thermal protection system (TPS) technologies required for future Outer Planet exploration missions. A prime conclusion is that several of the most significant recommendations made during the last decadal survey were addressed positioning the TPS community to better support missions to the Outer Planets. These include maturation of the Heatshield for Extreme Entry Environment Technology (HEEET) to TRL 6 as replacement for Carbon Phenolic (that requires requalification itself), TPS test facility upgrades, and design tool improvements. These new materials and test methods are enabling for Outer Planet missions. However, there are limitations in the HEEET technology and available ground based test facilities that could become mission constraints depending on the science objectives. This white paper discusses opportunities to mitigate those constraints. In addition, if a mission is not scheduled in the near future, these new developments are at risk of becoming unavailable. Therefore, we recommend that NASA invest in a cross-cutting technology program that focuses on sustainment of relevant TPS materials, entry systems, test facilities, design tools, and flight instrumentation.

Outer Planets↗

NASA NTRS1997

Surface Catalysis and Characterization of Proposed Candidate TPS for Access-to-Space Vehicles

Surface properties have been obtained on several classes of thermal protection systems (TPS) using data from both side-arm-reactor and arc-jet facilities. Thermochemical stability, optical properties, and coefficients for atom recombination were determined for candidate TPS proposed for single-stage-to-orbit vehicles. The systems included rigid fibrous insulations, blankets, reinforced carbon carbon, and metals. Test techniques, theories used to define arc-jet and side-arm-reactor flow, and material surface properties are described. Total hemispherical emittance and atom recombination coefficients for each candidate TPS are summarized in the form of polynomial and Arrhenius expressions.

Stewart, David A.↗