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Video highlighting the products and manufacturing capabilities of the Thermal Protection Facility at Kennedy Space Center which is part of the JSC EA/ES division. This record includes an mp4 video with a run time of 9 min. 13 sec.; in color; with sound.
The Manned Maneuvering Unit (MMU) and its support equipment provide an extravehicular astronaut mobility, and the ability to work outside the confines of the Shuttle Orbiter payload bay. The MMU design requirements are based on the highly successful Skylab M-509 maneuvering unit. Design of the MMU was started as an R&D effort in April 1975 and Flight Hardware design was started in August 1979 to support a possible requirement for in-space inspection and repair of Orbiter thermal protection tiles. Subsequently, the qualification test and production activities were slowed, and the current projected earliest first flight is now STS-11 in January, 1984. The MMU propulsion subsystem provides complete redundancy with two identical "system". Each system contains a high pressure gaseous nitrogen tank, an isolation valve, a regulator, and twelve 1.7 lbf (7.5 N) thrusters. The thrusters are packaged to provide the crew member six-degree-of-freedom control in response to commands from translational and rotational hand controllers. This paper discusses the MMU control arm requirements, design, and developmental history.
STS-114 Discovery crew is shown in various training exercises at Johnson Space Center. The crew consists of Eileen Collins, Commander; James Kelley, Pilot; Charles Camarda, Mission Specialist; Wendy Lawrence, Mission Specialist; Soichi Noguchi, Mission Specialist; Steve Robinson, Mission Specialist; and Andy Thomas, Mission Specialist. The exercises include: 1) EVA training in the VR lab; 2) Neutral Buoyancy Laboratory (NBL) EVA Training; 3) Walk to Motion Base Simulator; 4) EVA Preparations in ISS Airlock; and 7) Emergency Egress from Crew Compartment Trainer (CCT). A crew photo session is also presented. Footage of The Space Shuttle Atlantis inside the Kennedy Space Center Vehicle Assembly Building (VAB) after its demating from the Solid Rocket Booster and External Tank is shown. The video ends with techniques for inspecting and repairing Thermal Protection System tiles, a video of external tank production at the Michoud Assembly Facility (MAF) and redesign of the foam from the bipod ramp at Michoud Assembly Facility (MAF).
This viewgraph presentation provides an overview of the Space Shuttle Thermal Protection System (TPS) and the various products incorporated in the TPS. There are three tile systems which include pure silica, fibrous refractory composite insulation (FRCI), and alumina enhanced thermal barrier (AETB). Coating systems include reaction cured glass (RCG) and toughened uni-piece insulation (TUFI). The microstructures of these systems are explored as are the manufacturing processes associated with each. Microstructural investigation using methods such as automated X-ray spectral image analysis (AXSIA) is a crucial part of understanding the mechanical nature of these systems.
NASA/Ames' Hypervelocity Free-Flight Radiation Facility has been reactivated after having been decommissioned for some 15 years, first tests beginning in early 1994. This paper discusses two widely different studies from the first series, one involving spectroscopic analysis of model shock-layer radiation, and the other the production of representative impact damage in space shuttle thermal protection tiles for testing in the Ames arc-jet facilities. These studies emphasize the interorganizational and interdisciplinary value of the facility in the newly-developing structure of NASA.
Six fiber products and six insulation blankets comprising silica, alumina, zirconia, mullite, and mixed ceramic systems were subjected to furnace exposures up to 500 hours at temperatures of 1000 to 1600 C and evaluated for chemical and dimensional stability and for changes in thermal conductivity. Alumina, zirconia, and mullite fibers were fabricated into reusable surface insulation (RSI) tile by water-felting and reimpregnation with ethyl silicate. Specimens were exposed to 25 thermal cycles at 1200 C and 1400 C and a pressure of 10 and 32 torr, respectively. Production costs for 930 sq m (10,000 sq ft) of blanket insulation and of alumina RSI tile were developed.
As part of the research and development program to develop new Thermal Protection System (TPS) materials for aerospace applications at NASA's Marshall Space Flight Center (MSFC), an experimental study was conducted on a new concept for a non-ablative TPS material. Potential loss of TPS material and ablation by-products from the External Tank (ET) or Solid Rocket Booster (SRB) during Shuttle flight with the related Orbiter tile damage necessitates development of a non-ablative thermal protection system. The new Thermal Management Coating (TMC) consists of phase-change material encapsulated in micro spheres and a two-part resin system to adhere the coating to the structure material. The TMC uses a phase-change material to dissipate the heat produced during supersonic flight rather than an ablative material. This new material absorbs energy as it goes through a phase change during the heating portion of the flight profile and then the energy is slowly released as the phase-change material cools and returns to its solid state inside the micro spheres. The coating was subjected to different test conditions simulating design flight environments at the NASA/MSFC Improved Hot Gas Facility (IHGF) to study its performance.
The High-Granularity Calorimeter (HGCAL), part of the upgrade to the Compact Muon Solenoid (CMS) experiment, employs silicon and scintillator tile modules in the endcaps to maintain detector performance during the High-Luminosity Large Hadron Collider (HL-LHC) era, scheduled to operate from 2030 to 2040. The upgraded calorimeter will provide highly segmented three-dimensional imaging, energy measurements, and precise timing for particle shower reconstruction. Approximately half of the HGCal plastic scintillator tile modules (1,834 total) will be assembled at Fermilab using an automated pick-and-place (PnP) machine. Following assembly, each tile module undergoes quality control (QC) procedures such as electrical validation, thermal testing, and physics validation using cosmic rays. This poster/talk presents the QC procedures and results from the tile module production in 2026, demonstrating the performance and quality of the assembled tile modules.
The optical, thermal, and chemical properties of glass make it an ideal material for use in a wide range of applications, from optics and chemistry reactionware to consumer products. Tomographic volumetric additive manufacturing (tVAM) creates 3D objects by selectively gelling material within a rotating vial of photo-sensitive material by exposure to a series of tomographically-determined images. Here, in this study, tVAM is investigated for fabrication of complex, centimeter-scale, 3D silica glass parts. By optimizing the post-processing procedure, fully-dense glass parts with up to 2 cm 2 cross sectional area are achieved. The changes in optical properties during printing are leveraged for in situ metrology during printing, and the non-Newtonian nature of the glass-filled photoresin system to facilitate larger fabrication volumes via tiled projections. Printed structures are finally demonstrated for applications as MEMS components, optics, fluidics, and consumer products.
A visible emission spectroscopic method was developed. The amounts of excited singlet and triplet oxygen molecules produced by recombination on the Space Shuttle Orbiter thermal protective tiles at elevated temperatures are determined. Rate constants and energetics of the extremely exothermic reaction are evaluated in terms of a chemical and mathematical model. Implications for potential contribution to Shuttle surface reentry heating fluxes are outlined.
The Space Transportation System (STS) orbiters are known to be significant sources of outgassing in low earth orbit (LEO). Infrared and mass spectra of residues and outgassing from orbiter thermal protection tile and an external blanket are presented. Several sources of methyl and phenyl methyl silicones are identified. About fifty pounds of silicones are estimated to be outgassed during an STS mission.
In the design of microcalorimeters, it is often desirable to produce the X-ray absorber separately from the detector element. In this case, the attachment of the absorber to the detector element with the required thermal and mechanical characteristics is a major challenge. In such arrays, the attachment has been done by hand. This process is not easily extended to the large format arrays required for future X- ray astronomy missions such as the New x-ray Telescope or NeXT. In this paper we present an automated process for attaching absorber tiles to the surface of a large-scale X-ray detector array. The absorbers are attached with stycast epoxy to a thermally isolating polymer structure made of SU-8. SU-8 is a negative epoxy based photo resist produced by Microchem. We describe the fabrication of the X-ray absorbers and their suspension on a handle die in an adhesive matrix. We describe the production process for the polymer isolators on the detector elements. We have developed a new process for the alignment, and simultaneous bonding of the absorber tiles to an entire detector array. This process uses equipment and techniques used in the flip-chip bonding industry and approaches developed in the fabrication of the XRS-2 instrument. XRS-2 was an X-ray spectrometer that was launched on the Suzaku telescope in July 10, 2005. We describe the process and show examples of sample arrays produced by this process. Arrays with up to 300 elements have been bonded. The present tests have used dummy absorbers made of Si. In future work, we will demonstrate bonding of HgTe absorbers.
The detection of excited oxygen and ozone molecules formed by surface catalyzed oxygen atom recombination and reaction was investigated by laser induced fluorescence (LIF), molecular beam mass spectrometric (MBMS), and field ionization (FI) techniques. The experiment used partially dissociated oxygen flows from a microwave discharge at pressures in the range from 60 to 400 Pa or from an inductively coupled RF discharge at atmospheric pressure. The catalyst materials investigated were nickel and the reaction cured glass coating used for Space Shuttle reusable surface insulation tiles. Nonradiative loss processes for the laser excited states makes LIF detection of O2 difficult such that formation of excited oxygen molecules could not be detected in the flow from the microwave discharge or in the gaseous products of atom loss on nickel. MBMS experiments showed that ozone was a product of heterogeneous O atom loss on nickel and tile surfaces at low temperatures and that ozone is lost on these materials at elevated temperatures. FI was separately investigated as a method by which excited oxygen molecules may be conveniently detected. Partial O2 dissociation decreases the current produced by FI of the gas.
In this work, we generally expect quantum systems to thermalize and satisfy the eigenstate thermalization hypothesis (ETH), which states that finite-energy-density eigenstates are thermal. However, some systems, such as many-body localized systems and systems with quantum many-body scars, violate ETH and have high-energy athermal eigenstates. In systems with scars, most eigenstates thermalize, but a few atypical scar states do not. Scar states can give rise to a periodic revival when time-evolving particular initial product states, which can be detected experimentally. Recently, a family of spin Hamiltonians was found with magnetically ordered three-colored eigenstates that are quantum many-body scars [Lee et al., Phys. Rev. B 101, 241111(R) (2020)]. These models can be realized in any lattice that can be tiled by triangles, such as the triangular or kagome lattices, and have been shown to have close connections to the physics of quantum spin liquids in the Heisenberg kagome antiferromagnet. In this paper, we introduce a generalized family of n-colored Hamiltonians with “spiral colored” eigenstates made from n-spin motifs such as polygons or polyhedra. We show how these models can be realized in many different lattice geometries and provide numerical evidence that they can exhibit quantum many-body scars with periodic revivals that can be observed by time-evolving simple product states. The simple structure of these Hamiltonians makes them promising candidates for future experimental studies of quantum many-body scars.
Room temperature vulcanizing (RTV) silicone is a high-temperature adhesive used as a gap-filler between heatshield tiles in numerous entry missions. Its propensity to intumesce, or swell upon exposure to heat, is a well-known effect that needs to be carefully quantified during design. At tile interfaces of charring ablators, intumescence, combined with differential recession, could cause the gap filler to protrude past the ablator outer mold line, forming a “fence”. Fencing can in turn cause transition to turbulence of the flow wetting the heat shield, leading to augmented surface heating. Recent experiments conducted at the Plasmatron X facility, the high enthalpy wind tunnel of the Center for Hypersonics and Entry Systems Studies, have shown prominent fencing of RTV gap fillers in PICA, under both nitrogen and air plasmas. Similar observations are well known in the arcjet literature. Further experiments under controlled environment, performed using in situ X-ray micro-computed tomography (micro-CT) at the Advanced Light Source (ALS), have shown heating rate-dependent swelling and shrinkage of RTV during pyrolysis. To simulate RTV intumescence, a novel model was introduced in the Porous Materials Analysis Toolbox based on OpenFOAM, PATO, to account for pore-pressure buildup within both closed- and open-pores. The governing equation for the thermo-poro-mechanical response were developed, assuming linear elasticity for the charring silicone. A new multi-pyrolysis model that tracks non-monotonic advancement of material properties with pyrolysis was proposed. This model addresses the limitations of state-of-the-art ablator models to capture the different stages of thermal degradation and coupled thermomechanics. Swelling of RTV was simulated using the new thermo-poro-mechanical model and compared against in situ micro-CT data. Results showed good agreement in intumescence height and temperature profiles at all heating rates, indicating that the key factor contributing to RTV swelling is the internal pressure build-up within closed- and open-pores. As RTV is cured into a soft (rubbery) compound with low-porosity and permeability, initial temperature increase and pyrolysis gas production cause a significant increase of internal pressure, causing a pronounced volume growth. As thermal degradation progresses, rigidization of the silicone occurs due to char hardening which counteract volume shrinkage after gas pressure relief. Overall, our model shows that accounting for changes in properties such porosity, permeability and key thermomechanical coefficients is crucial for capturing the RTV volume change during ablation and enable a predictive capability for heatshield tile interface response. A plan for future calibration of thermomechanical properties evolution during degradation is discussed, as a key next step to close the new model.
Room temperature vulcanizing (RTV) silicone is a high-temperature adhesive used as a gap-filler between heatshield tiles in numerous entry missions. Its propensity to intumesce, or swell upon exposure to heat, is a well-known effect that needs to be carefully quantified during design. At tile interfaces of charring ablators, intumescence, combined with differential recession, could cause the gap filler to protrude past the ablator outer mold line, forming a “fence”. Fencing can in turn cause transition to turbulence of the flow wetting the heat shield, leading to augmented surface heating. Recent experiments conducted at the Plasmatron X facility, the high enthalpy wind tunnel of the Center for Hypersonics and Entry Systems Studies, have shown prominent fencing of RTV gap fillers in PICA, under both nitrogen and air plasmas. Similar observations are well known in the arcjet literature. Further experiments under controlled environment, performed using in situ X-ray micro-computed tomography (micro-CT) at the Advanced Light Source (ALS), have shown heating rate-dependent swelling and shrinkage of RTV during pyrolysis. To simulate RTV intumescence, a novel model was introduced in the Porous Materials Analysis Toolbox based on OpenFOAM, PATO, to account for pore-pressure buildup within both closed- and open-pores. The governing equation for the thermo-poro-mechanical response were developed, assuming linear elasticity for the charring silicone. A new multi-pyrolysis model that tracks non-monotonic advancement of material properties with pyrolysis was proposed. This model addresses the limitations of state-of-the-art ablator models to capture the different stages of thermal degradation and coupled thermomechanics. Swelling of RTV was simulated using the new thermo-poro-mechanical model and compared against in situ micro-CT data. Results showed good agreement in intumescence height and temperature profiles at all heating rates, indicating that the key factor contributing to RTV swelling is the internal pressure build-up within closed- and open-pores. As RTV is cured into a soft (rubbery) compound with low-porosity and permeability, initial temperature increase and pyrolysis gas production cause a significant increase of internal pressure, causing a pronounced volume growth. As thermal degradation progresses, rigidization of the silicone occurs due to char hardening which counteract volume shrinkage after gas pressure relief. Overall, our model shows that accounting for changes in properties such porosity, permeability and key thermomechanical coefficients is crucial for capturing the RTV volume change during ablation and enable a predictive capability for heatshield tile interface response. A plan for future calibration of thermomechanical properties evolution during degradation is discussed, as a key next step to close the new model.
Insulative thermal protection systems, such as Flexible Reusable Surface Insulation blankets and High Temperature Reusable Surface Insulation tiles, were developed for the Shuttle Orbiter to enable reuse of the vehicle for low-earth orbit missions. Since reusability is essential to many new industry launch and space vehicles, Shuttle-derived thermal protection materials (TPMs) are being sought for their flight proven performance. Alumina Enhanced Thermal Barrier (AETB) is the state-of-the-art tile material that was developed in the 90’s. AETB along with associated coatings, reaction cured glass (RCG) and Toughened Unipiece Fibrous Insulation (TUFI), are currently made by NASA using heritage raw materials derived from lifetime purchases. Finding viable replacements for raw materials that have changed in nature or are obsolete is important for continuation of these TPMs. In some cases, the use of modern raw materials has been shown to yield tile with reduced performance, most notably in mechanical properties. In this work, the production of AETB will be discussed to better understand the process-structure-property relationships and for allowing use of these modern alternatives. A small-scale tile casting system was developed for rapid and efficient exploration of the manufacturing variables such raw material selection and pre-processing, casting process parameters, and billet firing protocols. An optical transmission defect characterization technique was implemented to correlate process variables to structure. Comparisons between TUFI/RCG coated AETB derived from heritage and modern raw materials will be shown including AHF arc jet test results completed under a collaboration with Stratolaunch.
This article describes collaborative research between Shell International Exploration and Production (IE&P) scientists and ISAG personnel to investigate the feasibility of ultrasonic-based characterization of spacecraft tile damage for in-space inspection applications. The approach was proposed by Shell personnel in a Shell-NASA "speed-matching" session in early 2011 after ISAG personnel described challenges inherent in the inspection of MMOD damage deep within spacecraft thermal protection system (TPS) tiles. The approach leveraged Shell's relevant sensor and analytical expertise. The research addressed the difficulties associated with producing 3D models of MMOD damage cavities under the surface of a TPS tile, given that simple image-based sensing is constrained by line of sight through entry holes that have diameters considerably smaller than the underlying damage cavities. Damage cavity characterization is needed as part of a vehicle inspection and risk reduction capability for long-duration, human-flown space missions. It was hoped that cavity characterization could be accomplished through the use of ultrasonic techniques that allow for signal penetration through solid material.