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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRSDate not supplied

An Approach to Critical Ablative TPS Capabilities Sustainment for Future NASA Missions

We plan to present an approach for NASA to maintain critical ablative TPS capabilities through small, sus-tained, smart and targeted investment. Historically, we have been pound foolish and penny wise for decades and paid very little attention to sustainability of abla-tive TPS and as a result, spent couple of decades in learning what we lost and inventing newer technology solutions. NASA’s ablative TPS history has been one of in-vesting in new and unique capabilities in anticipation of needs, and once flight proven, letting the capability atrophy due to lack of subsequent near-term mission needs [1]. When the need arises, NASA has resorted to two options: (1) revive the capability at considerable cost impact, or (2) develop an alternate capability with considerable schedule impact. Both these options have had considerable mission impact. The third alternate is to maintain proven capabilities in a cost effective manner. A risk informed decision process in terms of maintaining ablative TPS capabilities is feasible with planning and sustained support. Assured TPS availa-bility will allow the science community to propose competed missions with confidence and at a lower risk for selection. We submitted a white paper to the cur-rent Decadal Survey [2] on the need for and im-portance of sustainability. Since then, we have been formulating an executable cost effective strategy. The intent of this presentation is to outline the develop-ments since the submission of the white paper. NASA and DoD have had a working group related to critical technologies to periodically assess and make recommendations on at-risk items from a national need perspective. This inter-agency working group typically focuses on raw materials availability. While we agree that at-risk raw materials are important, fo-cus solely on them is not sufficient. Instead, we advo-cate for a broader focus that includes not only raw material but also industrial manufacturing and processing, and NASA expertise in design, testing and flight hardware certification. In this proposed presentation, we will give a brief overview of NASA’s ablative TPS history along with recent examples of atrophy to highlight case studies related to the PICA and Carbon-Phenolic TPS. We will present the rationale for sustaining PICA, HEEET and 3MDCP for future NASA missions. We will present an approach for how targeted small investments could lead to maintaining mission critical capabilities over long periods.

E Venkatapathy↗
NASA NTRS2011

Advanced Ablative TPS

Early NASA missions (Gemini, Apollo, Mars Viking) employed new ablative TPS that were tailored for the entry environment. After 40 years, heritage ablative TPS materials using Viking or Pathfinder era materials are at or near their performance limits and will be inadequate for future exploration missions. Significant advances in TPS materials technology are needed in order to enable any subsequent human exploration missions beyond Low Earth Orbit. This poster summarizes some recent progress at NASA in developing families of advanced rigid/conformable and flexible ablators that could potentially be used for thermal protection in planetary entry missions. In particular the effort focuses technologies required to land heavy (approx.40 metric ton) masses on Mars to facilitate future exploration plans.

Gasch, Matthew J.↗
NASA NTRSDate not supplied

Ablative TPS Sustainment to Enable NASA's Future Robotic Missions

Since 1960s NASA’s missions have spanned the entire solar system, from Apollo to Jupiter entry ~50 km/s. Ablative TPS has been critical to the success. NASA’s missions will continue to be innovative, one-of-a kind and at the same time, competed mission selection process requires technology readiness to be high to ensure cost and risks are better understood. If missions require new TPS technology, it takes a decade and significant resources to develop them. Competitive proposal tend to use existing ablative TPS. Sustainability of ablative TPS is then essential. This talk will focus on approaches to address the future challenges.

Ethiraj Venkatapathy↗
NASA NTRS2004

TPS Ablator Technologies for Interplanetary Spacecraft

This slide presentation reviews the status of Thermal Protection System (TPS) Ablator technologies and the preparation for use in interplanetary spacecraft. NASA does not have adequate TPS ablatives and sufficient selection for planned missions. It includes a comparison of shuttle and interplanetary TPS requirements, the status of mainline TPS charring ablator materials, a summary of JSC SBIR accomplishments in developing advanced charring ablators and the benefits of SBIR Ablator/fabrication technology.

Curry, Donald M.↗
NASA NTRSDate not supplied

Critical Ablative TPS Capabilities Sustainment - An Approach to Playing the Long Game

Historically, we have been pound foolish and penny wise for decades, and it is time to reverse this. We present an approach that will maintain critical NASA ablative TPS capabilities through small, sustained, smart and targeted investment. NASA’s ablative TPS history is one of developing new capabilities and letting them atrophy. When needed, there are two options: (1) revive the capability at considerable cost impact or (2) develop an alternate capability with considerable schedule impact. Either of these options have had considerable mission impact. The third alternate is to maintain proven capabilities in a cost effective manner to allow the science community to propose missions with confidence. NASA and DoD have had a working group to periodically assess and make recommendations on at-risk items. This working group typically focuses on raw materials availability. While we agree that at-risk raw materials are an important and necessary part of the overall capability, focus solely on them is not sufficient. Instead, we advocate for a broader focus on the critical “technology capability” that includes not only raw material but also industrial manufacturing and processing capabilities and in-house expertise in design, testing and flight hardware certification. In this proposed presentation, we will highlight a case study related to PICA capability. We will present the rationale for sustaining PICA and HEEET as two minimum essential ablative TPS capabilities for future NASA missions. We will present an approach for how small investment could lead to maintaining mission critical capabilities over a longer period. While HEEET and PICA are NASA unique, the raw material and some of the vendor capabilities involved also support DoD TPS. Hence a partnership between NASA and DoD is recommended for broader benefit.

Ethiraj Venkatapathy↗
NASA NTRS2016

Development of Advanced Conformal Ablative TPS Fabricated from Rayon- and PAN-Based Carbon Felts

The conformal ablative TPS first developed under NASA's Hypersonics Project in the early 2000's demonstrated very low through the thickness conductivity compared to state-ofthe- art PICA. However, in initial arcjet testing of Conformal-1, surface recession rates were 2x higher than PICA. Because commercial carbon felts are currently available as very thin substrates, this was a concern if conformal TPS were to be considered for a mission that required thicker material. Discussed in this paper are the results of the development of an Advanced Conformal TPS derived from thicker, higher density carbon felt. Two substrate systems were evaluated, the first material was a needled rayon-based carbon felt and the other a needled PAN-based carbon felt. Both substrates were impregnated with phenolic resin following the PICA/CPICA process to add a low density phenolic matrix to the system prior to aerothermal screening at the LaRC HyMETS facility and larger scale testing in the NASA ARC Interaction Heating Facility (IHF) at heating fluxes ranging from 250-1700 W/cm2.

Arcjet Testing↗
NASA NTRS2013

Testing of Advanced Conformal Ablative TPS

In support of the CA250 project, this paper details the results of a test campaign that was conducted at the Ames Arcjet Facility, wherein several novel low density thermal protection (TPS) materials were evaluated in an entry like environment. The motivation for these tests was to investigate whether novel conformal ablative TPS materials can perform under high heat flux and shear environment as a viable alternative to rigid ablators like PICA or Avcoat for missions like MSL and beyond. A conformable TPS over a rigid aeroshell has the potential to solve a number of challenges faced by traditional rigid TPS materials (such as tiled Phenolic Impregnated Carbon Ablator (PICA) system on MSL, and honeycomb-based Avcoat on the Orion Multi Purpose Crew Vehicle (MPCV)). The compliant (high strain to failure) nature of the conformable ablative materials will allow better integration of the TPS with the underlying aeroshell structure and enable monolithic-like configuration and larger segments to be used in fabrication.A novel SPRITE1 architecture, developed by the researchers at NASA Ames was used for arcjet testing. This small probe like configuration with 450 spherecone, enabled us to test the materials in a combination of high heat flux, pressure and shear environment. The heat flux near the nose were in the range of 500-1000 W/sq cm whereas in the flank section of the test article the magnitudes were about 50 of the nose, 250-500W/sq cm range. There were two candidate conformable materials under consideration for this test series. Both test materials are low density (0.28 g/cu cm) similar to Phenolic Impregnated Carbon Ablator (PICA) or Silicone Impregnated Refractory Ceramic Ablator (SIRCA) and are comprised of: A flexible carbon substrate (Carbon felt) infiltrated with an ablative resin system: phenolic (Conformal-PICA) or silicone (Conformal-SICA). The test demonstrated a successful performance of both the conformable ablators for heat flux conditions between 50-500 W/sq cm. The recession and temperature profile for these materials were comparable to PICA proving them to be viable alternatives for TPS technology development for future missions.

Gasch, Matthew↗
NASA NTRS2013

Modern Advances in Ablative TPS

Topics covered include: Physics of Hypersonic Flow and TPS Considerations. Destinations, Missions and Requirements. State of the Art Thermal Protection Systems Capabilities. Modern Advances in Ablative TPS. Entry Systems Concepts. Flexible TPS for Hypersonic Inflatable Aerodynamic Decelerators. Conformal TPS for Rigid Aeroshell. 3-D Woven TPS for Extreme Entry Environment. Multi-functional Carbon Fabric for Mechanically Deployable.

Venkatapathy, Ethiraj↗
NASA NTRS2017

Parametric Study of an Ablative TPS and Hot Structure Heatshield for a Mars Entry Capsule Vehicle

The National Aeronautics and Space Administration is planning to send humans to Mars. As part of the Evolvable Mars Campaign, different en- try vehicle configurations are being designed and considered for delivering larger payloads than have been previously sent to the surface of Mars. Mass and packing volume are driving factors in the vehicle design, and the thermal protection for planetary entry is an area in which advances in technology can offer potential mass and volume savings. The feasibility and potential benefits of a carbon-carbon hot structure concept for a Mars entry vehicle is explored in this paper. The windward heat shield of a capsule design is assessed for the hot structure concept as well as an ablative thermal protection system (TPS) attached to a honeycomb sandwich structure. Independent thermal and structural analyses are performed to determine the minimum mass design. The analyses are repeated for a range of design parameters, which include the trajectory, vehicle size, and payload. Polynomial response functions are created from the analysis results to study the capsule mass with respect to the design parameters. Results from the polynomial response functions created from the thermal and structural analyses indicate that the mass of the capsule was higher for the hot structure concept as compared to the ablative TPS for the parameter space considered in this study.

Langston, Sarah L.↗
NASA NTRSDate not supplied

Analysis of Pyrolysis Products from Ablative TPS

NASA’s state-of-the-art ablative materials are composed of a three-dimensional network of carbon fibers impregnated with polymers that dissipate thermal energy through pyrolysis. A fundamental understanding of the decomposition mechanisms and pyrolysis product distributions of various classes of polymers is instrumental in the design of new ablative materials. Furthermore, innovative experiments are essential to the continuous modernization of material response models by providing high-fidelity data. Thus, an apparatus has been designed to measure pyrolysis products from polymers and composite materials by implementing in-situ mass spectrometric techniques. Initial results from experiments performed on siloxane resins and a common phenolic resin will be discussed. Both classes of polymers exhibit heating-rate-dependent decomposition mechanisms. At the onset of heating, phenolic polymers decompose through competitive reactions to form gaseous products and a carbonaceous char. Gas phase products of phenolic resins are typically composed of molecular hydrogen, water, and aromatic hydrocarbons. Pyrolysis products from siloxane polymers include molecular hydrogen, small molecules, and cyclic oligomers from the polymer.

Pyrolysis↗
NASA NTRS2014

Arcjet Testing of Advanced Conformal Ablative TPS

A conformable TPS over a rigid aeroshell has the potential to solve a number of challenges faced by traditional rigid TPS materials (such as tiled Phenolic Impregnated Carbon Ablator (PICA) system on MSL. The compliant (high strain to failure) nature of the conformable ablative materials will allow integration of the TPS with the underlying aeroshell structure much easier and enable monolithic-like configuration and larger segments (or parts) to be used. In May of 2013 the CA250 project executed an arcjet test series in the Ames IHF facility to evaluate a phenolic-based conformal system (named Conformal-PICA) over a range of test conditions from 40-400Wcm2. The test series consisted of four runs in the 13-inch diameter nozzle. Test models were based on SPRITE configuration (a 55-deg sphere cone), as it was able to provide a combination of required heat flux, pressure and shear within a single entry. The preliminary in-depth TC data acquired during that test series allowed a mid-fidelity thermal response model for conformal-PICA to be created while testing of seam models began to address TPS attachment and joining of multiple segments for future fabrication of large-scale aeroshells. Discussed in this paper are the results.

Arcjet Testing↗
NASA NTRS2012

Aerothermal Testing of Woven TPS Ablative Materials

Woven Thermal Protection Systems (WTPS) is a new TPS concept that is funded by NASAs Office of the Chief Technologist (OCT) Game Changing Division. The WTPS project demonstrates the potential for manufacturing a variety of TPS materials capable of wide ranging performances demanded by a spectrum of solar system exploration missions. Currently, missions anticipated to encounter heat fluxes in the range of 1500 4000 Watts per square centimeter are limited to using one proven material fully dense Carbon Phenolic. However, fully dense carbon phenolic is only mass efficient at heat fluxes greater than 4000 Watts per square centimeter, and current mission designs suffer this mass inefficiency for lack of an alternative mid-density TPS. WTPS not only bridges this gap but also offers a replacement for carbon phenolic, which itself requires a significant and costly redevelopment effort to re-establish its capability for use in the high heat flux missions recently prioritized in the NRC Decadal survey, including probe missions to Venus, Saturn and Neptune. This poster will summarize some recent arc jet testing to evaluate the performance of WTPS. Both mid density and fully dense WTPS test results will be presented and results compared to heritage carbon phenolic where applicable.

Stackpoole, Mairead↗
NASA NTRSDate not supplied

Three Dimensionally Woven Mid-Density Carbon Phenolic (3MDCP) is a Novel Single Piece Ablative TPS for Extreme Entry Environments

Three Dimensionally Woven Mid-Density Carbon Phenolic (3MDCP) is robust, single piece, carbon phenolic ablative thermal protection system under development at NASA Ames Research Center initially for the Mars Sample Return Earth Entry System (MSR EES). The MSR EES requirements drove the need for TPS with no seams, capable of surviving the highest entry conditions for any NASA Earth return capsule with heat fluxes >2000 W/cm2 and pressures >1.5 atmospheres. To produce 3MDCP required development of new weaving infrastructure to enable weaving of preforms large enough to form into a single piece heatshield. It required development of forming techniques to transform a flat woven panel into a sphere cone shape and enhanced infusion processes to support larger scale infusion of resin into the formed preforms. A rigorous performance testing campaign was conducted to develop and validate the materials thermal response model used to determine the required material thickness and to demonstrate the material can survive the extreme entry conditions. The end of the development effort (end of FY26) will result in a TPS at Technical Readiness Level (TRL) 6 and Manufacturing Readiness Level (MRL) 6+ for the MSR EES mission and a mature system ready to support other missions. This poster will provide a snapshot of where 3MDCP is in its development phase.

Ablator↗
NASA NTRS2011

Advanced Rigid Ablative TPS

NASA Exploration Systems Mission Directorate s (ESMD) Entry, Descent, and Landing (EDL) Technology Development Project (TDP) and the NASA Aeronautics Research Mission Directorate s (ARMD) Hypersonics Project are developing new advanced rigid ablators in an effort to substantially increase reliability, decrease mass, and reduce life cycle cost of rigid aeroshell-based entry systems for multiple missions. Advanced Rigid Ablators combine ablation resistant top layers capable of high heat flux entry and enable high-speed EDL with insulating mass-efficient bottom that, insulate the structure and lower the areal weight. These materials may benefit Commercial Orbital Transportation Services (COTS) vendors and may potentially enable new NASA missions for higher velocity returns (e.g. asteroid, Mars). The materials have been thermally tested to 400-450 W/sq cm at the Laser Hardened Materials Evaluation Lab (LHMEL), Hypersonics Materials Evaluation Test System (HyMETS) and in arcjet facilities. Tested materials exhibit much lower backface temperatures and reduced recession over the baseline materials (PICA). Although the EDL project is ending in FY11, NASA in-house development of advanced ablators will continue with a focus on varying resin systems and fiber/resin interactions.

Gasch, Matthew J.↗
NASA NTRSDate not supplied

Tutorial on Ablative TPS

No abstract. This unrestricted presentation was written by Bernie Laub and Don Curry in 2004.

Ablative materials↗
NASA NTRSDate not supplied

Overview of Ablative TPS Modeling at NASA Ames

Over the past decade, NASA has invested in efforts to build predictive thermal protection system (TPS) material models from the micro-scale to the macro-scale. To complement the mission design cycle process and reduce the need for extensive testing, NASA is developing modeling and simulation tools that enable characterizing material properties and response to hot plasma experienced during atmospheric entry. Traditional material response and ablation modeling tools, such as the heritage code FIAT, and its multidimensional siblings, TITAN and 3dFIAT, are being complemented with newly developed software such as Icarus and PATO. Both of these programs are three-dimensional, finite-volume solvers that use unstructured meshes and 21st century programming paradigms to allow for efficient parallel simulations. FIAT and Icarus are also used for TPS sizing purposes. Today, these traditional tools are being supplemented with computational materials models at the atomistic level. The scales of interest range from computational chemistry (Density Functional Theory [DFT]), to atomistic simulations (Molecular Dynamics [MD]), to the microscale with the Porous Microstructure Analysis (PuMA) software that was recently awarded the 2022 NASA Software of the Year award. Finally, thermo-structural modeling is also of interest to the TPS Materials branch and done using commercial tools such as MSC MARC, MENTAT, NASTRAN and PATRAN. The present talk will also link the use of these computational tools to current NASA missions and projects associated with challenging and complex vehicles entries/reentries.

materials modeling↗
NASA NTRSDate not supplied

Nasa’S Development of Merino - A New Family of Advanced, Low-Cost, Non-Woven Ablative Tps Materials

The Mars Exploration Program (MEP) and NASAs Space Technology Mission Directorate (STMD) are investing in approaches to reduce the cost and increase the frequency of future Mars missions while also seeking to help emerging commercial space companies which have an immediate need to demonstrate their capability to return samples from space - at a fraction of the cost of a conventional NASA mission. Of particular interest and relevance to commercial space and low-cost Mars, is the work developing and advancing MERINO-LD, an ablative carbon/phenolic blanket that is ~75% faster to produce with an estimated ~75% reduction in cost when compared to rigid PICA or Conformal-PICA TPS.

Matthew Gasch↗