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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Heat Flux and Pressure Envelope Expansion Tests of Phenolic Impregnated Carbon Ablator (PICA)

Phenolic Impregnated Carbon Ablator (PICA) is a frequently employed thermal protection system (TPS) material in the space flight community. First flown on the forebody of Stardust, which re-entered in January of 2006, PICA has been the go-to material system for each successive Martian rover mission. This legacy continues with PICA domestic (PICA-D) baselined for the Mars Sample Retrieval Lander (SRL) and Dragon-fly, a mission to Titan’s surface. In mission planning, the capability of a TPS material system is restricted to environments that are proven through ground testing or flight missions. De-spite the range of destinations from Earth return to Mars entry to Saturn moons, PICA’s demonstrated capability currently covers heating rates less than 1800 W/cm2 and surface pressures less than 150 kPa [1]. These recognized limitations prevent PICA for consideration in direct entry applications at Venus, the outer planets, and high mass return missions at Earth, thus requiring selecting higher density materials [2].

PICA Arc-jet Testing Envelope↗
NASA NTRS2019

Sustaining Phenolic Impregnated Carbon Ablator (PICA) for Future NASA Missions Including Discovery and New Frontiers

Phenolic Impregnated Carbon Ablator (PICA) was invented in the mid 1990's and due to its relatively low density and efficient performance has been the heat shield TPS of choice for a range of missions includ-ing, Stardust, OSIRIS-Rex, Mars Science Laboratry (MSL) and Mars 2020. PICA has also been the TPS solution on numerous Discovery and New Frontiers proposals, as both the heat shield and back shell TPS and is under consideration as both for the Mars Sample Return Earth Entry Vehicle (EEV) and the heat shield on the Sample Retrieval Lander (SRL). Recently NASA's Science Mission Directorate (SMD) has funded an activity to develop a more sus-tainable version of PICA and to expand the demon-strated capabilities of PICA both in manufacturing and aerothermal performance.

Thermal Protection Material↗
NASA NTRS2016

Investigation of Performance Envelope for Phenolic Impregnated Carbon Ablator (PICA)

The present work provides the results of a short exploratory study on the performance of Phenolic Impregnated Carbon Ablator, or PICA, at high heat flux and pressure in an arcjet facility at NASA Ames Research Center. The primary objective of the study was to explore the thermal response of PICA at cold-wall heat fluxes well in excess of 1500 W/cm (exp 2). Based on the results of a series of flow simulations, multiple PICA samples were tested at an estimated cold wall heat flux and stagnation pressure of 1800 W/cm (exp 2) and 130 kPa, respectively. All samples survived the test, and no failure was observed either during or after the exposure. The results indicate that PICA has a potential to perform well at environments with significantly higher heat flux and pressure than it has currently been flown.

Ablative Material↗
NASA NTRS2015

Pressure Venting Tests of Phenolic Impregnated Carbon Ablator (PICA)

A series of tests was devised to investigate the pressure venting behavior of one of the candidate ablators for the Orion capsule heat shield. Three different specimens of phenolic impregnated carbon ablator (PICA) were instrumented with internal pressure taps and subjected to rapid pressure changes from near vacuum to one atmosphere and simulated Orion ascent pressure histories. The specimens vented rapidly to ambient pressure and sustained no detectable damage during testing. Peak pressure differences through the thickness of a 3-inch-thick specimen were less than 1 psi during a simulated ascent pressure history.

Blosser, Max L.↗
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

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 NTRS2019

Development of Lyocell Based Phenolic Impregnated Carbon Ablators (PICA-D) for Future 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 1999. Due to the obsolescence of the input fiber source, new PICA materials were developed using Lyocell, a domestic rayon fiber source. Results are presented from this effort. Manufacturing included fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet testing have been conducted. Initial testing indicates comparable performance with respect to heritage PICA material, and likely "drop-in" replacement for future NASA mission needs.

Thermal Protection↗
NASA NTRS2019

Development of Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future 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 1999. Due to the obsolescence of the input fiber source, new PICA materials were developed using Lyocell, a domestic rayon fiber source. Results are presented from this effort. Manufacturing included fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet testing have been conducted. Initial testing indicates comparable performance with respect to heritage PICA material, and likely "drop-in" replacement for future NASA mission needs.

thermal protection↗
NASA NTRS2019

Development of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future 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. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification 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. Results are presented from this effort including fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Initial testing of PICA-Domestic (PICA-D) indicates comparable performance with respect to "heritage" PICA materials and thus PICA-D is expected to be a sustainable solution for future NASA missions.

Drop-In Replacement↗
NASA NTRS2019

Development of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future 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. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification 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. Results are presented from this effort including fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Initial testing of PICA-Domestic (PICA-D) indicates comparable performance with respect to "heritage" PICA materials and thus PICA-D is expected to be a sustainable solution for future NASA missions.

Drop-In Replacement↗
NASA NTRS2015

Thermal Protection System Mass Estimating Relationships for Blunt-Body, Earth Entry Spacecraft

System analysis and design of any entry system must balance the level fidelity for each discipline against the project timeline. One way to inject high fidelity analysis earlier in the design effort is to develop surrogate models for the high-fidelity disciplines. Surrogate models for the Thermal Protection System (TPS) are formulated as Mass Estimating Relationships (MERs). The TPS MERs are presented that predict the amount of TPS necessary for safe Earth entry for blunt-body spacecraft using simple correlations that closely match estimates from NASA's high-fidelity ablation modeling tool, the Fully Implicit Ablation and Thermal Analysis Program (FIAT). These MERs provide a first order estimate for rapid feasibility studies. There are 840 different trajectories considered in this study, and each TPS MER has a peak heating limit. MERs for the vehicle forebody include the ablators Phenolic Impregnated Carbon Ablator (PICA) and Carbon Phenolic atop Advanced Carbon-Carbon. For the aftbody, the materials are Silicone Impregnated Reusable Ceramic Ablator (SIRCA), Acusil II, SLA-561V, and LI-900. The MERs are accurate to within 14% (at one standard deviation) of FIAT prediction, and the most any MER under predicts FIAT TPS thickness is 18.7%. This work focuses on the development of these MERs, the resulting equations, model limitations, and model accuracy.

mass estimating relationship (MER)↗
NASA NTRS2015

Thermal Protection System Mass Estimating Relationships For Blunt-Body, Earth Entry Spacecraft

Mass estimating relationships (MERs) are developed to predict the amount of thermal protection system (TPS) necessary for safe Earth entry for blunt-body spacecraft using simple correlations that are non-ITAR and closely match estimates from NASA's highfidelity ablation modeling tool, the Fully Implicit Ablation and Thermal Analysis Program (FIAT). These MERs provide a first order estimate for rapid feasibility studies. There are 840 different trajectories considered in this study, and each TPS MER has a peak heating limit. MERs for the vehicle forebody include the ablators Phenolic Impregnated Carbon Ablator (PICA) and Carbon Phenolic atop Advanced Carbon-Carbon. For the aftbody, the materials are Silicone Impregnated Reusable Ceramic Ablator (SIRCA), Acusil II, SLA- 561V, and LI-900. The MERs are accurate to within 14% (at one standard deviation) of FIAT prediction, and the most any MER can under predict FIAT TPS thickness is 18.7%. This work focuses on the development of these MERs, the resulting equations, model limitations, and model accuracy.

Spacecraft↗
NASA NTRS2014

Development Of FIAT-Based Parametric Thermal Protection System Mass Estimating Relationships For NASA's Multi-Mission Earth Entry Concept

An integrated tool called the Multi Mission System Analysis for Planetary Entry Descent and Landing (M-SAPE) is being developed as part of NASAs In-Space Propulsion Technology (ISPT) program. Part of M-SAPEs development requires the formulation of mass estimating relationships (MERs) to determine the vehicle's Thermal Protection System (TPS) material and required thickness for safe Earth entry. The objective of this study was to develop MERs using simple correlations that were non-ITAR and matched as accurately as possible NASAs high-fidelity ablation modeling tool, the Fully Implicit Ablation and Thermal Analysis Program (FIAT ). These MERs would be a first-estimate for feasibility studies; it is understood that higher-fidelity modeling like FIAT would be necessary once a proposed trajectory was down-selected. The trajectory space for these MERS consisted of 840 different trajectories, and a materials heating limit was the main constraint for an allowable trajectory. MERs for the vehicle fore body included the ablating materials Phenolic Impregnated Carbon Ablator (PICA ) and Carbon Phenolic atop Advanced Carbon-Carbon. For the backshell the materials were Silicone Impregnated Reusable Ceramic Ablator (SIRCA ), Acusil II, SLA-561V, and LI-900. The MERFIAT ratio indicates MERs are accurate to within 14 percent (at one standard deviation) of FIAT prediction, and the most any MER can under-predict TPS thickness is 18.7 percent of FIAT prediction. This poster focuses on the development of these MERs, the resulting equations, model limitations, and model accuracy.

thermal protection system↗
NASA NTRS2010

Fiber-Based Measurement of Bow-Shock Spectra for Reentry Flight Testing

We demonstrated a fiber-based approach for obtaining optical spectra of a glowing bow shock in a high-enthalpy air flow. The work was performed in a ground test with the NASA Ames Aerodynamic Heating Facility (AHF) that is used for atmospheric reentry simulation. The method uses a commercial fiber optic that is embedded in the nose of an ablating bluntbody model and provides a line-of-sight view in the streamwise direction - directly upstream into the hot post-shock gas flow. Both phenolic impregnated carbon ablator (PICA) and phenolic carbon (PhenCarb 28) materials were used as thermal protection systems. Results show that the fibers survive the intense heat and operate sufficiently well during the first several seconds of a typical AHF run (20 MJ/kg). This approach allowed the acquisition of optical spectra, enabling a Boltzmann-based electronic excitation temperature measurement from Cu atom impurities (averaged over a line-of-sight through the gas cap, with a 0.04 sec integration time).

Schott, Timothy D.↗
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 NTRS2006

Carbon Nanotube-Enhanced Carbon-Phenenolic Ablator Material

This viewgraph presentation reviews the use of PICA (phenolic impregnated carbon ablator) as the selected material for heat shielding for future earth return vehicles. It briefly reviews the manufacturing of PICA and the advantages for the use of heat shielding, and then explains the reason for using Carbon Nanotubes to improve strength of phenolic resin that binds carbon fibers together. It reviews the work being done to create a carbon nanotube enhanced PICA. Also shown are various micrographic images of the various PICA materials.

Kikolaev, P.↗
NASA NTRS2018

Estimation of Heatshield Mass Loss for Mars 2020 Entry Vehicle

The Mars2020 entry vehicle is currently being developed by NASA to safely land its next rover on the Martian surface in 2021. During entry, the vehicle will be protected from aerothermal environments using a PICA (Phenolic Impregnated Carbon Ablator)-tiled heatshield. PICA loses mass through surface recession and in-depth pyrolysis as it is heated. Pre-flight knowledge of heatshield mass loss is required for vehicle balancing during critical mission events. This study attempts to predict the total mass loss experienced by the Mars2020's heatshield during its entry. A grid was created over the half of the heatshield which generated 108 points across a total of 9 spokes. Aero-thermal environments were provided from CFD (Computational Fluid Dynamics) calculations that considered a baselined trajectory. The TPS (Thermal Protection System) stack was a build-up of composite, aluminum, composite, an HT-424 bond, followed by PICA. The FIAT (Fully Implicit Ablation, Thermal-response) 1-D analysis utilized this TPS stack and the CFD environments and was run at each grid point giving mass flux information from the point of atmospheric entry until parachute deployment. The mass flux due to recession and pyrolysis gas was summed and integrated first through time and then across the half heatshield using a polar integration tool. The mass loss results were mirrored to the other half of the heatshield to calculate total mass loss throughout the entry phase of flight. This total mass loss value and its distribution was used by entry vehicle designers to account for CG (Center of Gravity) offset during parachute descent when the heatshield is no longer losing significant mass.

PICA↗
NASA NTRS2011

PICA Variants with Improved Mechanical Properties

Phenolic Impregnated Carbon Ablator (PICA) is a member of the family of Lightweight Ceramic Ablators (LCAs) and was developed at NASA Ames Research Center as a thermal protection system (TPS) material for the Stardust mission probe that entered the Earth s atmosphere faster than any other probe or vehicle to date. PICA, carbon fiberform base and phenolic polymer, shows excellent thermal insulative properties at heating rates from about 250 W/sq cm to 1000 W/sq cm. The density of standard PICA - 0.26 g/cu cm to 0.28 g/cu cm - can be changed by changing the concentration of the phenolic resin. By adding polymers to the phenolic resin before curing it is possible to significantly improve the mechanical properties of PICA without significantly increasing the density.

Thornton, Jeremy↗