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NASA NTRS2012

Lessons Learned in the Decommissioning of the Stardust Spacecraft

The Stardust spacecraft completed its prime mission in 2006, returning samples from the coma of comet Wild 2 to earth in the sample return capsule. Still healthy, and in a heliocentric orbit, the Stardust spacecraft was repurposed for a new mission - Stardust NExT. This new mission would take the veteran spacecraft to a 2011 encounter with comet Tempel 1, providing a new look at the comet visited in 2005 by the Deep Impact mission. This extended mission for Stardust would push it to the limits of its fuel reserves, prompting several studies aimed at determining the actual remaining fuel on board. The results were used to plan mission events within the constraints of this dwindling resource. The team tracked fuel consumption and adjusted the mission plans to stay within the fuel budget. This effort intensified toward the end of the mission, when a final assessment showed even less remaining fuel than previously predicted, triggering a delay in the start of comet imaging during the approach phase. The flyby of comet Tempel 1 produced spectacular up close views of this comet, imaging previously seen areas as well as new territory, and providing clear views of the location of the 2005 impact. The spacecraft was decommissioned about a month after the flyby, revealing that the fuel tank was now empty after having flown successfully for 12 years, returned comet dust samples to earth, and flown by an asteroid and two comets.

repurposed spacecrafts↗
NASA NTRS2003

Software Searches for Better Spacecraft-Navigation Models

ADAPT is a computer program that searches for better mathematical models for spacecraft navigation. The task of tuning trajectory-determination models for interplanetary navigation is complex, requiring an intensive search of multiple dynamical and nondynamical models that yield trajectory solutions with minimal errors. By automating the search, ADAPT eases the task of human analysts and enables them to consider wider ranges of potential solutions. ADAPT uses genetic algorithms to search a range of relevant parameters in a user-selected design space to arrive at values for those parameters that best fit the measured spacecraft-tracking data. The user s guide for ADAPT reviews the theoretical basis of the program and presents two example applications. One example is that of selecting a solar-radiation model for the Mars Pathfinder (MPF) mission using MPF tracking data and an extended Kalman filter from prior spacecraft-navigation software. The second example is of the use of tracking data from the Stardust spacecraft mission combined with a pseudo-epoch-state batch filter and an empirical small-forces model to find improved impulse models for use during Stardust attitude adjustments.

Ely, Todd↗
NASA NTRS2024

Chemical and Physical Properties of Cometary Dust

Cometary dust particles are best preserved remnants of the matter present at the onset of the formation of the Solar System. In Space missions, telescopic observations and laboratory analyses advanced the knowledge on the properties of cometary dust. the only samples certified with a cometary origin were returned by the Stardust space mission from comet 81P/Wild2. The “chondritic porous” (here called “chondritic anhydrous”) interplanetary dust particles (CA-IDPs) and micrometeorites (CP-MMs), and the ultracarbonaceous Antarctic MMs (UCAMMs) also show strong evidence for a cometary origin. The elemental composition of cometary dust is generally consistent with the chondritic (CI) composition, with the notable exception of elevated contents in carbon and nitrogen compared with CI. The organic matter of cometary dust is mixed with minor amounts of crystalline (at least 25% of the minerals) and amorphous mineral phases. The most abundant crystalline minerals are ferromagnesian silicates (olivine and low-Ca pyroxenes), but High-Ca pyroxenes, refractory minerals and Low Ni Fe sulfides are also present. The crystalline olivine and low-Ca pyroxene compositions can vary from their Mg-rich end-member (forsterite and enstatite) to relatively Fe-rich compositions. Refractory minerals as well as secondary minerals likeLIME (low-iron, Mn-enriched) olivines, unusual Fe sulfides or mineral aggregates of specific compositions like Kosmochloric high-Ca pyroxene and FeO-rich olivine - KOOL grains) are also found. The presence of carbonates in cometary dust is still debated, but a phyllosilicate-like phase was observed in a UCAMM. The abundance of pyroxene to olivine (in numbers) is larger than in primitive meteorites (e.g. the Px/Ol ratio is usually larger than 1). GEMS phases (glass with embedded metals and sulfides) are abundant in cometary dust, although not systematically found. Some of the organic matter present in cometary dust particle resembles the insoluble organic matter (IOM) present in primitive meteorites, but amorphous carbon and exotic (e.g. N-rich) organic phases are also present. The hydrogen isotopic composition of cometary dust particles (in the organic matter) is usually rich in deuterium, tracing a formation at very low temperatures, either in the protosolar cloud or in the outer regions of the protoplanetary disk. The presolar dust concentration in cometary dust can reach about 1%, which is the most elevated value observed in extraterrestrial samples. The size distribution of cometary dust in comet trails is well represented by a power-law distribution (differential size distribution) with a mean power index N typically ranging from -3 to -4. Polarimetric and light scattering studies of cometary dust suggest mixtures of porous agglomerates of sub-micrometer minerals with organic matter, which is compatible with the in situ analyses of 67P/Churyumov-Gerasimenko by MIDAS (Rosetta) and with the studies of it Stardust samples, CA-IDPs, CP-MMs and UCAMMs. Cometary dust particles have low tensile strength, and low density.

C. Engrand↗
NASA NTRS2008

Preliminary Examination of the Interstellar Collector of Stardust

The findings of the Stardust spacecraft mission returned to earth in January 2006 are discussed. The spacecraft returned two unprecedented and independent extraterrestrial samples: the first sample of a comet and the first samples of contemporary interstellar dust. An important lesson from the cometary Preliminary Examination (PE) was that the Stardust cometary samples in aerogel presented a technical challenge. Captured particles often separate into multiple fragments, intimately mix with aerogel and are typically buried hundreds of microns to millimeters deep in the aerogel collectors. The interstellar dust samples are likely much more challenging since they are expected to be orders of magnitudes smaller in mass, and their fluence is two orders of magnitude smaller than that of the cometary particles. The goal of the Stardust Interstellar Preliminary Examination (ISPE) is to answer several broad questions, including: which features in the interstellar collector aerogel were generated by hypervelocity impact and how much morphological and trajectory information may be gained?; how well resolved are the trajectories of probable interstellar particles from those of interplanetary origin?; and, by comparison to impacts by known particle dimensions in laboratory experiments, what was the mass distribution of the impacting particles? To answer these questions, and others, non-destructive, sequential, non-invasive analyses of interstellar dust candidates extracted from the Stardust interstellar tray will be performed. The total duration of the ISPE will be three years and will differ from the Stardust cometary PE in that data acquisition for the initial characterization stage will be prolonged and will continue simultaneously and parallel with data publications and release of the first samples for further investigation.

Westphal, A. J.↗
NASA NTRS2013

Advanced Aerogel Technology

The JPL Aerogel Laboratory has made aerogels for NASA flight missions, e.g., Stardust, 2003 Mars Exploration Rovers and the 2011 Mars Science Laboratory, as well as NASA research projects for the past 14 years. During that time it has produced aerogels of a range of shapes, sizes, densities and compositions. Research is ongoing in the development of aerogels for future sample capture and return missions and for thermal insulation for both spacecraft and scientific instruments. For the past several years, the JPL Aerogel Laboratory has been developing, producing and testing a new composite material for use as the high temperature thermal insulation in the Advanced Sterling Radioisotope Generator (ASRG) being developed by Lockheed Martin and NASA. The composite is made up of a glass fiber felt, silica aerogel, Titania powder, and silica powder. The oxide powders are included to reduce irradiative heat transport at elevated temperatures. These materials have thermal conductivity values that are the same as the best commercially produced high temperature insulation materials, and yet are 40% lighter. By greatly reducing the amount of oxide powder in the composite, the density, and therefore for the value of the thermal conductivity, would be reduced. The JPL Aerogel Laboratory has experimented with using glass fiber felt, expanded glass fiber felt and loose fibers to add structural integrity to silica aerogels. However, this work has been directed toward high temperature applications. By conducting a brief investigation of the optimal combination of fiber reinforcement and aerogel density, a durable, extremely efficient thermal insulation material for ambient temperature applications would be produced. If a transparent thermal insulation is desired, then aerogel is an excellent candidate material. At typical ambient temperatures, silica aerogel prevents the transport of heat via convection and conduction due to its highly porous nature. To prevent irradiative thermal transport, silica aerogel can be used in conjunction with a transparent polymeric material that blocks infrared radiation. The transparency of silica aerogel is typically greater than 90% for visible wavelengths from 500 nm to 900 nm for a 5 mm long path length.

reduce irradiative heat transport↗
NASA NTRS2009

Detection of Cometary Amines in Samples Returned by the Stardust Spacecraft

The delivery of amino acids to the early Earth by comets and their fragments could have been a significant source of the early Earth's prebiotic organic inventory that led to the emergence of life (Chyba and Sagan, 1992). Over 20 organic molecules including methane, ethane, ammonia, cyanic acid, formaldehyde, formamide, acetaldehyde, acetonitrile, and methanol have been identified by radio spectroscopic observations of the comae of comets Hale-Bopp and Hyakutake (Crovisier et al. 2004). These simple molecules could have provided the organic reservoir to allow the formation of more complex prebiotic organic compounds such as amino acids. After a 7-year mission, the Stardust spacecraft returned to Earth samples from comet Wild 2 on January 15, 2006 providing the opportunity to analyze the organic composition and isotopic distribution of cometary material with state-of-the-art laboratory instrumentation. The Preliminary Examination Team analyses of organics in samples returned by Stardust were largely focused on particles that impacted the collector aerogel and aluminum foil (Sandford et al. 2006). However, it is also possible that Stardust returned a "diffuse" sample of gas-phase organic molecules that struck the aerogel directly or diffused away from the grains after impact. To test this possibility, samples of Stardust flight aerogel and foil were carried through a hot water extraction and acid hydrolysis procedure to see if primary amine compounds were present in excess of those seen in controls. Here we report highly sensitive liquid chromatography time-of-flight mass spectrometry measurements of amino acids and amines in samples returned from a comet (Glavin et al. 2008). A suite of amino acids and amines including glycine, L-alanine, methylamine (MA), and ethylamine (EA) were identified in the Stardust bulk aerogel. With the exception of MA and EA, all other primary amines detected in comet-exposed aerogels were also present in the aerogel witness tile that was not exposed to Wild 2, suggesting that most amines are terrestrial in origin. However, the enhanced abundances of MA, EA, and possibly glycine in comet-exposed aerogel compared to controls, coupled with MA to EA ratios (1 to 2) that are distinct from preflight aerogels (7 to 10), suggest that these amines were captured from Wild 2. It is possible that MA and EA were formed on energetically processed icy grains containing methane, ethane, and ammonia. The presence of cometary amines in Stardust material supports the hypothesis that comets were an important source of prebiotic organics on the early Earth. To better understand their origin, a systematic compound specific carbon isotopic analysis (C-CSIA) via gas chromatography quadrupole mass spectrometry in with parallel with combustion isotope ratio mass spectrometry (GCQMS/ IRMS) is being conducted. We will discuss our latest C-CSIA measurements and what they indicate about the origin of amino acids extracted from Stardust samples.

Glavin, Daniel P.↗
NASA NTRS2010

Detection of Cometary Amines in Samples Returned by the Stardust Spacecraft

The delivery of amino acids to the early Earth by comets and their fragments could have been a significant source of the early Earth's prebiotic organic inventory that led to the emergence of life (Chyba and Sagan, 1992). Over 20 organic molecules including methane, ethane, ammonia, cyanic acid, formaldehyde, formamide, acetaldehyde, acetonitrile, and methanol have been identified by radio spectroscopic observations of the comae of comets Hale-Bopp and Hyakutake (Crovisier et al. 2004). These simple molecules could have provided the organic reservoir to allow the forn1ation of more complex prebiotic organic compounds such as amino acids. After a 7 -year mission, the Stardust spacecraft returned to Earth samples from comet Wild 2 on January 15, 2006 providing the opportunity to analyze the organic composition and isotopic distribution of cometary material with state-of-the-art laboratory instrun1entation. The Preliminary Examination Team analyses of organics in samples returned by Stardust were largely focused on particles that impacted the collector aerogel and aluminum foil (Sandford et al. 2006). However, it is also possible that Stardust returned a "diffuse" sample of gas-phase organic molecules that struck the aerogel directly or diffused away from the grains after impact. To test this possibility, samples of Stardust flight aerogel and foil were carried through a hot water extraction and acid hydrolysis procedure to see if primary amine compounds were present in excess of those seen in controls. Here we report highly sensitive liquid chromatography time-of-flight mass spectron1etry measurements of amino acids and amines in samples returned from a comet (Glavin et al. 2008). A suite of amino acids and amines including glycine, L-alanine, methylamine (MA), and ethylamine (EA) were identified in the Stardust bulk aerogel. With the exception of MA and EA, all other primary amines detected in comet-exposed aerogels were also present in the aerogel witness tile that was not exposed to Wild 2, suggesting that most amines are terrestrial in origin. However, the enhanced abundances of MA, EA, and possibly glycine in comet-exposed aerogel compared to controls, coupled with MA to EA ratios (1 to 2) that are distinct from preflight aerogels (7 to 10), suggest that these amines were captured from Wild 2. It is possible that MA and EA were formed on energetically processed icy grains containing methane, ethane, and ammonia. The presence of cometary amines in Stardust material supports the hypothesis that comets were an important source of pre biotic organics on the early Earth. To better understand their origin, a systematic compound specific carbon isotopic analysis (C-CSIA) via gas chromatography quadrupole mass spectrometry in with parallel with combustion isotope ratio mass spectrometry (GC-QMS/IRMS) is being conducted. We will discuss our latest C-CSIA measurements and what they indicate about the origin of amino acids extracted from Stardust samples.

Glavin, Daniel P.↗
NASA NTRS2000

Stardust Navigation Covariance Analysis

The Stardust spacecraft was launched on February 7, 1999 aboard a Boeing Delta-II rocket. Mission participants include the National Aeronautics and Space Administration (NASA), the Jet Propulsion Laboratory (JPL), Lockheed Martin Astronautics (LMA) and the University of Washington. The primary objective of the mission is to collect in-situ samples of the coma of comet Wild-2 and return those samples to the Earth for analysis. Mission design and operational navigation for Stardust is performed by the Jet Propulsion Laboratory (JPL). This paper will describe the extensive JPL effort in support of the Stardust pre-launch analysis of the orbit determination component of the mission covariance study. A description of the mission and it's trajectory will be provided first, followed by a discussion of the covariance procedure and models. Predicted accuracy's will be examined as they relate to navigation delivery requirements for specific critical events during the mission. Stardust was launched into a heliocentric trajectory in early 1999. It will perform an Earth Gravity Assist (EGA) on January 15, 2001 to acquire an orbit for the eventual rendezvous with comet Wild-2. The spacecraft will fly through the coma (atmosphere) on the dayside of Wild-2 on January 2, 2004. At that time samples will be obtained using an aerogel collector. After the comet encounter Stardust will return to Earth when the Sample Return Capsule (SRC) will separate and land at the Utah Test Site (UTTR) on January 15, 2006. The spacecraft will however be deflected off into a heliocentric orbit. The mission is divided into three phases for the covariance analysis. They are 1) Launch to EGA, 2) EGA to Wild-2 encounter and 3) Wild-2 encounter to Earth reentry. Orbit determination assumptions for each phase are provided. These include estimated and consider parameters and their associated a-priori uncertainties. Major perturbations to the trajectory include 19 deterministic and statistical maneuvers planned for the mission. The spacecraft is three axis stabilized and has unbalanced thrusters for attitude control. Accelerations due to the attitude control system are treated stochastically. The tracking scenario for the study is patterned after the actual schedule employed during the different phases of the mission. Conventional X-band two-way Doppler and SRA range data was simulated and the standard accuracy for these data types was assumed throughout most of the mission. However, a deweighting scheme was used for the Doppler data during times of low Sun-Earth-Probe angles, especially in the case of the DSM. Optical data is assumed to be available starting at 50 days prior to the comet encounter. The optical data will be used to improve the ephemeris of Wild-2, which is considered crucial to properly target the comet flyby. Results of the covariance analysis are presented for all mission phases. Navigation capability will be discussed in terms of the uncertainty in the encounter B-Plane (B.R and B.T) and linearized time of flight. Delivery errors based on the final maneuver prior to the comet encounter will be presented. The most stringent navigation requirement is for the Earth reentry. The uncertainty in the flight path angle must be less than 0.02 degree (orbit determination and maneuver performance) to assure successful recovery of the SRC. Results presented show that this requirement can be met.

Menon, Premkumar R.↗
NASA NTRS2004

Asteroid 5535 Annefrank size, shape, and orientation: Stardust first results

The NASA Discovery Stardust spacecraft flew by the main belt asteroid 5535 Annefrank at a distance of 3100 km and a speed of 7.4 km/s in November 2002 to test the encounter sequence developed for its primary science target, the comet 81P/Wild2. During this testing, over 70 images of Annefrank were obtained, taken over a phase angle range from 40 to 140 degrees.

Asteroids NASA Stardust Mission↗
NASA NTRS2004

Stardust Encounters Comet 81P/Wild 2

Stardust successfully encountered comet 81P/Wild 2 on 2 January 2004 at a distance of 236.4 +/- 1 km. All encounter investigations acquired valuable new and surprising findings. The time-of-flight spectrometer registered 29 spectra during flyby and measured the first negative ion mass spectra of cometary particles. The dust detectors recorded particles over a broad mass range, 10(exp -11) to 10(exp -4) g. Unexpectedly, the dust distribution along Stardust's flight path was far from uniform, but instead occurred in short 'bursts', suggesting in-flight breakup of fragments ejected from the nucleus. High-resolution, stunning images of the Wild 2 surface show a diverse and complex variety of landforms not seen from comets 1P/Halley and 19P/Borrelly or icy satellites of the outer solar system. Longer-exposure images reveal large numbers of jets projected nearly around the entire perimeter of the nucleus, many of which appear to be highly collimated. A triaxial ellipsoidal fit of the Wild 2 nucleus images yields the principal nucleus radii of 1.65 X 2.00 X2.75 km (+/- 0.05 km). The orientations and source locations on the nucleus surface of 20 highly collimated and partially overlapping jets have been traced. There is every indication that the expected samples were successfully collected from the Wild 2 coma and are poised for a return to Earth on 15 January 2006.

Stardust mission↗
NASA NTRS2011

Deep Impact, Stardust-NExT and the Behavior of Comet 9P/Tempel 1 from 1997 to 2010

We present observational data for Comet 9P/Tempel 1 taken from 1997 through 2010 in an international collaboration in support of the Deep Impact and Stardust-NExT missions. The data were obtained to characterize the nucleus prior to the Deep Impact 2005 encounter, and to enable us to understand the rotation state in order to make a time of arrival adjustment in February 2010 that would allow us to image at least 25% of the nucleus seen by the Deep Impact spacecraft to better than 80 m/pixel, and to image the crater made during the encounter, if possible. In total, approx.500 whole or partial nights were allocated to this project at 14 observatories worldwide, utilizing 25 telescopes. Seventy percent of these nights yielded useful data. The data were used to determine the linear phase coefficient for the comet in the R-band to be 0.045 +/- 0.001 mag/deg from 1deg to 16deg. Cometary activity was observed to begin inbound near r approx. 4.0 AU and the activity ended near r approx. 4.6 AU as seen from the heliocentric secular light curves, water-sublimation models and from dust dynamical modeling. The light curve exhibits a significant pre- and post-perihelion brightness and activity asymmetry. There was a secular decrease in activity between the 2000 and 2005 perihelion passages of approx. 20%. The post-perihelion light curve cannot be easily explained by a simple decrease in solar insolation or observing geometry. CN emission was detected in the comet at 2.43 AU pre-perihelion, and by r = 2.24 AU emission from C2 and C3 were evident. In December 2004 the production rate of CN increased from 1.8 x 10(exp 23) mol/s to Q(sub CN) = 2.75 x 10(exp 23) mol/s in early January 2005 and 9.3 x 10(exp 24) mol/s on June 6, 2005 at r = 1.53 AU.

Meech, K. J.↗
NASA NTRS2015

Alternative High Performance Polymers for Ablative Thermal Protection Systems

Ablative thermal protection systems are commonly used as protection from the intense heat during re-entry of a space vehicle and have been used successfully on many missions including Stardust and Mars Science Laboratory both of which used PICA - a phenolic based ablator. Historically, phenolic resin has served as the ablative polymer for many TPS systems. However, it has limitations in both processing and properties such as char yield, glass transition temperature and char stability. Therefore alternative high performance polymers are being considered including cyanate ester resin, polyimide, and polybenzoxazine. Thermal and mechanical properties of these resin systems were characterized and compared with phenolic resin.

Ablator↗
NASA NTRS2017

Fine-Gained CAIs in Comet Samples: Moderate Refractory Character and Comparison to Small Refractory Inclusions in Chondrites

Examination of >200 comet Wild 2 particles collected by the Stardust (SD) mission shows that the CAI abundance of comet Wild 2's rocky material is near 1% and that nearly 50% of all bulbous tracks will contain at least one recognizable CAI fragment. A similar abundance to Wild 2 is found in a giant cluster IDP thought to be of cometary origin. The properties of these CAIs and their comparison with meteoritic CAIs provide important clues on the role of CAIs in the early Solar System (SS) and how they were transported to the edge of the solar nebula where Kuiper Belt comets formed. Previously, only two CAIs in comet Wild 2 had been identified and studied in detail. Here we present 2 new Wild 2 CAIs and 2 from a giant cluster cometary IDP, describe their mineralogical characteristics and show that they are most analogous to nodules in spinel-rich, fine-grained inclusions (FGIs) observed in CV3 and other chondrites. Additionally, we present new O isotope measurements from one CAI from comet Wild 2 and show that its oxygen isotopic composition is similar to some FGIs. This is only the second CAI from Wild 2 in which O isotopes have been measured.

Joswiak, D. J.↗
NASA NTRS2019

Characterization of New TPS Resins

Ablative thermal protection systems are commonly used as protection from the intense heat during re-entry of a space vehicle and have been used successfully on many missions including Stardust and Mars Science Laboratory both of which used PICA a phenolic based ablator. Historically, phenolic resin has served as the ablative polymer for many TPS systems. However, it has limitations in both processing and properties such as char yield, glass transition temperature and char stability. Therefore alternative high performance polymers are being considered such as: cyanate ester resin, polyimide, polybenzoxazine (PBZ), and polyimidazole (PBI).Thermal and mechanical properties of these four resin systems were characterized and compared with phenolic resin.

Boghozian, T.↗
NASA NTRSDate not supplied

Investigating Material Behavior in Atmospheric Entry Conditions: Arc-Jet Testing Insights from Meteorite Ablation to High-Temperature Coatings.

Arc-jet testing is an indispensable tool in elucidating the complex interactions materials undergo when subjected to the extreme thermal and mechanical stresses of atmospheric entry. By replicating these harsh conditions, arc-jets enable researchers to explore critical phenomena such as ablation, melting, and spallation, generating invaluable data that informs the development of sophisticated, physics-based models. These models are pivotal not only in predicting material performance for spacecraft re-entry systems but also in assessing the threat posed by celestial bodies as they encounter Earth’s atmosphere. One of the leading facilities for such investigations is the Hypersonic Materials Environmental Test System (HyMETS) at NASA’s Langley Research Center. A pioneering test campaign conducted at HyMETS focused on unraveling the ablation mechanisms of an ordinary chondrite meteorite (Tamdakht H5) and a terrestrial analog (basalt). These studies unveiled distinct material behaviors: Tamdakht demonstrated a remarkably stable melt flow, with mass loss primarily driven by the volatilization of elements such as iron and sodium, whereas basalt exhibited more aggressive surface degradation due to the rapid decomposition of hydrated minerals, culminating in significant spallation and surface material ejection. Beyond meteorite analysis, HyMETS has also been integral in the exploration of advanced Thermal Protection Systems (TPS) such as Phenolic Impregnated Carbon Ablator (PICA), a material with extensive flight heritage in missions like Stardust, Mars Science Laboratory, Mars 2020, and Osiris-REx. PICA, when coated with NuSil CV-1144-0—a polysiloxane resin designed to prevent particle shedding—undergoes a remarkable transformation upon heating. The resin pyrolyzes to form a thin, oxidation-resistant silicon oxycarbide layer that profoundly influences the material’s thermal response through a sophisticated four-stage process. Initially, the silicon oxycarbide acts as a formidable barrier, impeding reactive interactions with the PICA char and effectively suppressing surface temperature rise and material recession. However, as the heating persists, the protective layer decomposes via carbothermal reduction, exposing the underlying char, which in turn leads to a dramatic spike in surface temperature and accelerated material erosion. In the final stage, equilibrium is reached, with recession rates aligning with those of the virgin material. This intricate understanding of PICA-NuSil behavior under extreme conditions offers valuable insights, enhancing material response models and advancing the development of next-generation TPS for space exploration.

Chemistry↗
NASA NTRSDate not supplied

Qualification of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90’s. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions, from Sample Return missions such as Stardust, OSIRIS-REx to large Mars Lander missions such as Mars Science Lab (MSL) and Mars 2020. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues. The challenge involved in finding a replacement fiber source is in processing as well as in the final performance of the ablator. Each replacement necessitates the requalification of the PICA. This has happened at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Due to its flight heritage and proven capability, PICA is baselined as the Thermal Protection System (TPS) for Dragonfly and Mars Sample Return Sample Retrieval Lander mission and is being considered for the backshell of the Mars Sample Return Earth Entry System. All three missions are due to be launched between 2026 and 2028. The challenge this time is to ensure the PICA made with domestic material is a suitable replacement to the heritage PICA used in MSL and Mars 2020 so that the design of the heatshield can be matured without much risk. Results are presented from the recent efforts of 22 PICA-D billets that were Lot Acceptance Tested. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Testing of PICA-Domestic (PICA-D) indicates very comparable performance with respect to “heritage” PICA materials and thus PICA-D is expected to be a sustainable and nearly a “drop-in” replacement solution for future NASA missions.

Matt Gasch↗
NASA NTRSDate not supplied

Qualification of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90’s. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions, from Sample Return missions such as Stardust, OSIRIS-REx to large Mars Lander missions such as Mars Science Lab (MSL) and Mars 2020. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues. The challenge involved in finding a replacement fiber source is in processing as well as in the final performance of the ablator. Each replacement necessitates the requalification of the PICA. This has happened at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Due to its flight heritage and proven capability, PICA is baselined as the Thermal Protection System (TPS) for Dragonfly and Mars Sample Return Sample Retrieval Lander mission and is being considered for the backshell of the Mars Sample Return Earth Entry System. All three missions are due to be launched between 2026 and 2028. The challenge this time is to ensure the PICA made with domestic material is a suitable replacement to the heritage PICA used in MSL and Mars 2020 so that the design of the heatshield can be matured without much risk. Results are presented from the recent efforts of 22 PICA-D billets that were Lot Acceptance Tested. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Testing of PICA-Domestic (PICA-D) indicates very comparable performance with respect to “heritage” PICA materials and thus PICA-D is expected to be a sustainable and nearly a “drop-in” replacement solution for future NASA missions.

PICA↗
NASA NTRSDate not supplied

Development of Advanced Conformal and Soft Pica for Future Nasa Missions and Commercial Space

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90’s. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions, from Sample Return missions such as Stardust, OSIRIS-REx to large Mars Lander missions such as MSL and Mars 2020. Continued development of a more mass efficient and compliant versions of PICA that use a carbon felt as the substrate will be presented. The felt based versions of PICA known as Conformal PICA (C-PICA) and Soft PICA (S-PICA), are very comparable in terms of peak heat-flux capabilities compared to standard PICA. The lower density and of C-PICA and S-PICA further show a much higher thermal protection efficiency and hence more mass savings. The compliant nature of these materials allows for use on a wide variety of substrates and therefore makes it very attractive for commercial low earth orbit missions as well as NASA’s aerocapture missions to Ice Giants. NASA is currently working with several commercial partners (Varda and Inversion Space) to Technology Transfer C/S-PICA variants for commercial LEO missions. Thermal, mechanical, and representative environment arc-jet tests have been conducted comparing the performance of Conformal and Soft-PICA materials.

Matthew J Gasch↗