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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Thermostructural responses of carbon phenolics in a restrained thermal growth test

The thermostructural response of carbon phenolic components in a solid rocket motor (SRM) is a complex process. It involves simultaneous heat and mass transfer along with chemical reactions in a multiphase system with time-dependent material properties and boundary conditions. In contrast to metals, the fracture of fiber-reinforced composites is characterized by the initiation and progression of multiple failures of different modes such as matrix cracks, interfacial debonding, fiber breaks, and delamination. The investigation of thermostructural responses of SRM carbon phenolics is further complicated by different failure modes under static and dynamic load applications. Historically, there have been several types of post-firing anomalies found in the carbon phenolic composites of the Space Shuttle SRM nozzle. Three major failure modes which have been observed on SRM nozzles are pocketing (spallation), ply-lift, and wedge-out. In order to efficiently control these anomalous phenomena, an investigation of fracture mechanisms under NASA/MSFC RSRM (Redesigned Solid Rocket Motor) and SPIP (Solid Propulsion Integrity Program) programs have been conducted following each anomaly. This report reviews the current progress in understanding the effects of the thermostructural behavior of carbon phenolics on the failure mechanisms of the SRM nozzle. A literature search was conducted and a technical bibliography was developed to support consolidation and assimilation of learning from the RSRM and SPIP investigation efforts. Another important objective of this report is to present a knowledge-based design basis for carbon phenolics that combines the analyses of thermochemical decomposition, pore pressure stresses, and thermostructural properties. Possible areas of application of the knowledge-based design include critical material properties development, nozzle component design, and SRM materials control.

Wang, C. Jeff↗
NASA NTRSDate not supplied

Thermostructural Testing of PICA-D for NASA Planetary Science Missions

Phenolic Impregnated Carbon Ablator–Domestic (PICA‑D) has been selected as the heatshield thermal protection system (TPS) material for two upcoming NASA planetary science missions: the Dragonfly mission to Titan and the Mars Sample Retrieval Lander (SRL). Early testing revealed differences between PICA‑D and heritage PICA, particularly in in‑plane (IP) tensile stiffness and thermal expansion. Thermostructural analyses using Finite Element Method (FEM) tools subsequently predicted the potential for IP compressive failure in the near‑surface layers of PICA‑D under both Dragonfly and SRL flight environments. Over the past three years, the Dragonfly and SRL teams have carried out an extensive thermostructural qualification campaign to address these concerns and validate PICA‑D for flight. This effort began with a comprehensive mechanical property characterization program at Kratos test laboratories, which significantly improved understanding of PICA‑D mechanical behavior and increased the fidelity of FEM predictions. The teams also conducted six large‑scale test entries at the National Solar Thermal Test Facility (NSTTF) solar tower, exposing PICA‑D articles—including gap fillers and representative design features or flaws—to combined thermal and mechanical loads. The talk will summarize key findings from these mechanical and thermostructural test campaigns and present the current status of PICA‑D qualification for NASA’s planetary science missions.

TPS↗
NASA NTRS2011

Thermostructural Analysis of the SOFIA Fine Field and Wide Field Imagers Subjected to Convective Thermal Shock

The originally designed SOFIA aircraft configuration included a system to pre-cool the telescope cavity on the ground before flight, however, due to various factors in the history of the project that system was not installed. This lack of ground pre-cooling was thus the source of the concern over whether or not the imagers would be exposed to a potentially unsafe thermostructural environment when the telescope cavity door was opened at altitude. This concern was in addition to the already existing concern that the air temperature rate of change during flight (both at the same altitude as well as ascent or descent) could cause the imagers to be exposed to an unsafe thermostructural environment. Four optical components were identified as the components of concern - two of higher concern (one in each imager) and two of lower concern (one in each imager). The requirement was to perform transient, coupled thermostructural analyses to determine whether the stress would ever achieve unsafe levels in these components. The analysis effort began by analyzing one component, after which the analyses for the other components was deemed unnecessary.

Kostyk, Chris↗
NASA NTRSDate not supplied

Thermostructural Qualification of PICA-D for NASA Planetary Science Missions

Phenolic Impregnated Carbon Ablator (PICA) has been used as the heatshield TPS material for many NASA planetary science missions. Due to a supply issue with the heritage Rayon fibers used in PICA fabrication, NASA started a project in 2017 to develop a sustainable replacement for PICA using a domestic fiber source, named PICA-D. This material has been selected as the heatshield TPS material for two upcoming NASA planetary science missions, Dragonfly mission to Titan and Mars Sample Retrieval Lander (SRL). While most PICA-D thermal and mechanical properties are very similar to PICA, early test data suggest that PICA-D is stiffer in tension in the in-plane (IP) direction, with higher strength but lower strain-to-failure. Preliminary thermostructural analysis using Finite Element Methods (FEM) tools predict IP compressive failure in the near-surface layers of PICA-D, for both Dragonfly and SRL flight environments. This talk provides an overview of the thermostructural qualification plans for PICA-D. A two-pronged approach is being pursued to demonstrate that the material and heatshield design has adequate capability for both SRL and Dragonfly design environments. The first part is to improve the accuracy of analytical predictions through a comprehensive characterization of PICA-D mechanical properties. The second, and more critical, part of the qualification approach is a subsystem-level test of PICA-D to demonstrate material capability under flight-relevant combined mechanical and thermal loads. The team is currently preparing for two test series in Sandia’s Solar Tower facility, scheduled in September 2023 and focusing on PICA-D acreage, followed by additional tests in the Solar Tower and LHMEL facilities focusing on design features and repair methods.

TPS↗
NASA NTRS1975

Thermostructural test facilities for reentry vehicle nose tip materials

To provide a cost effective means of assessing the thermostructural performance of nosetip materials, the Air Force has developed and utilized two types of thermostructural facilities: ground simulation facilities and laboratory facilities. The capabilities of the currently available test facilities are summarized and compared.

Budde, C. L.↗
NASA NTRS1980

Thermostructural analyses of structural concepts for hypersonic cruise vehicles

A matrix of structural concepts suitable for Mach 5 hydrogen-fueled hypersonic vehicles are defined, and a thermostructural analysis of each is presented. The thermal environment encountered in this flight regime mandates hot structures of superalloy materials or insulated structures using more conventional materials such as titanium, aluminum, and composites. This paper compares the thermostructural performance of several concepts. The various structures are initially sized to carry a 2.5 g subsonic maneuver load. The structural weights are determined, and these components are then evaluated in a transient heating program along with various thermal protection systems to determine the minimum weight combination. The temperature profiles generated for these minimum weight solutions are used as input to a structural analysis along with a model of the appropriate structural concept to calculate thermal stresses. Generally, hot structure concepts have higher thermal stresses. In most cases, the thermal stresses are below the yield strength of the material. It is shown that integral tanks have weights similar to nonintegral tank concepts for the same level of technology. Moreover, an insulated tubular aluminum-composite structure with nonintegral tanks appear attractive for near-term vehicles.

Taylor, A. H.↗
NASA NTRS2005

Thermostructural Properties Of Sic/Sic Panels With 2.5d And 3d Fiber Architectures

CMC hot-section components in advanced engines for power and propulsion will typically require high cracking strength, high ultimate strength and strain, high creep- rupture resistance, and high thermal conductivity in all directions. In the past, NASA has demonstrated fabrication of a variety of SiC/SiC flat panels and round tubes with various 2D fiber architectures using the high-modulus high-performance Sylramic-iBN Sic fiber and Sic-based matrices derived by CVI, MI, and/or PIP processes. The thermo- mechanical properties of these CMC have shown state-of-the-art performance, but primarily in the in-plane directions. Currently NASA is extending the thermostructural capability of these SiC/SiC systems in the thru-thickness direction by using various 2.5D and 3D fiber architectures. NASA is also using specially designed fabrication steps to optimize the properties of the BN-based interphase and Sic-based matrices. In this study, Sylramic-iBN/SiC panels with 2D plain weave, 2.5D satin weave, 2.5D ply-to-ply interlock weave, and 3D angle interlock fiber architectures, all woven at AITI, were fabricated using matrix densification routes previously established between NASA and GEPSC for CVI-MI processes and between NASA and Starfire-Systems for PIP processes. Introduction of the 2.5 D fiber architecture along with an improved matrix process was found to increase inter-laminar tensile strength from 1.5 -2 to 3 - 4 ksi and thru-thickness thermal conductivity from 15-20 to 30-35 BTU/ft.hr.F with minimal reduction in in-plane strength and creep-rupture properties. Such improvements should reduce thermal stresses and increase the thermostructural operating envelope for SiC/SiC engine components. These results are analyzed to offer general guidelines for selecting fiber architectures and constituent processes for high-performance SiC/SiC engine components.

Yun, H. M.↗
NASA NTRS2012

Thermostructural Analysis of the SOFIA Fine Field and Wide Field Imagers Subjected to Convective Thermal Shock

The Stratospheric Observatory For Infrared Astronomy (SOFIA) is a highly modified Boeing 747-SP with a 17- ton infrared telescope installed in the aft portion of the aircraft. Unlike ground- and space-based platforms, SOFIA can deploy to make observations anytime, anywhere, in the world. The originally designed aircraft configuration included a ground pre-cool system, however, due to various factors in the history of the project, that system was not installed. This lack of ground pre-cooling was the source of the concern about whether or not the imagers would be exposed to a potentially unsafe thermostructural environment. This concern was in addition to the already-existing concern of some project members that the air temperature rate of change during flight (both at the same altitude as well as ascent or descent) could cause the imagers to be exposed to an unsafe thermostructural environment. Four optical components were identified as the components of concern: two of higher concern (one in each imager), and two of lower concern (one in each imager). The analysis effort began by analyzing one component, after which the analyses for the other components was deemed unnecessary. The purpose of this report is to document these findings as well as lessons learned from the effort.

Kostyk, Christopher B.↗
NASA NTRS1979

Thermostructural applications of heat pipes

The feasibility of integrating heat pipes in high temperature structure to reduce local hot spot temperature was evaluated for a variety of hypersonic aerospace vehicles. From an initial list of twenty-two potential applications, the single stage to orbit wing leading edge showed the greatest promise and was selected for preliminary design of an integrated heat pipe thermostructural system. The design consisted of a Hastelloy X assembly with sodium heat pipe passages aligned normal to the wing leading edge. A d-shaped heat pipe cross section was determined to be optimum from the standpoint of structural weight.

Peeples, M. E.↗
NASA NTRS1979

Thermostructural analysis of three structural concepts for reusable space vehicles

Three structural concepts are studied: (1) a state-of-the-art insulated aluminum skin-stringer structure; (2) a near-art insulated evacuated aluminum-alloy honeycomb structure; and (3) an advanced evacuated Rene 41 honeycomb hot structure. Each is evaluated for its thermostructural performance for each of the flight profiles (ascent, entry, and a recall or abort). Results indicate that (1) the state-of-the-art structure encounters negligible thermal stress; (2) the near-art structure has acceptable thermal stresses; and (3) the advanced structure will have thermal stress levels above the material allowables.

Taylor, A. H.↗
NASA NTRS1979

Thermostructural design of a carbon-carbon heatshield for a Jovian entry

The thermostructural response of three candidate carbon-carbon composites for the Jovian entry probe heatshield was investigated. The analysis for the three materials, Sandia Felt, Carbitex 700, and SAI 4-D weave carbon-carbon was conducted using a dual finite element approach which involved heat conduction as well as the structural response. A receding boundary due to ablation and inertial loads encountered by the probe were included. Severe cracking, circumferential and radial, and interlaminar shear failure was observed during the radiative heating pulse for the Sandia Felt and Carbitex 700 materials, respectively. The 4-D weave material showed no failures over the entire entry.

White, M. J.↗
NASA NTRS1982

Historical perspectives on thermostructural research at the NACA Langley Aeronautical Laboratory from 1948 to 1958

Research on structural problems associated with aerodynamic heating, conducted by the National Advisory Committee for Aeronautics (NACA) during its last decade are described. The text of a special presentation given at the NASA Symposium on Computational Aspects of Heat Transfer in Structure is presented. Some early thermostructural research activities using charts is also discussed. The prinicipal message of the paper is that although vehicle oriented research programs speed development of new technology for specific missions, too much effort may be expended on developing technology which is never used because a vehicle is never built. A healthy research program must provide freedom to explore new ideas that have no obvious applications at the time to generate the technology that makes important, unanticipated flight or vehicle opportunities possible.

Heldenfels, R. R.↗
NASA NTRS1989

Plasma torch testing for thermostructural evaluation of rocket motor nozzle materials

This paper presents data from the thermostructural testing of tape-wrapped carbon phenolic. This work has been performed with the use of a plasma torch and loading device in an effort to study the anomalous erosion characteristicfs of that seen in the Space Shuttle Solid Rocket Motor Nozzle STS-8A. Testing is conducted in an effort to determine conditions or parameters involved in this mode of failure.

Prince, Andrew S.↗
NASA NTRS1997

Thermostructural Behavior of a Hypersonic Aircraft Sandwich Panel Subjected to Heating on One Side

Thermostructural analysis was performed on a heated titanium honeycomb-core sandwich panel. The sandwich panel was supported at its four edges with spar-like substructures that acted as heat sinks, which are generally not considered in the classical analysis. One side of the panel was heated to high temperature to simulate aerodynamic heating during hypersonic flight. Two types of surface heating were considered: (1) flat-temperature profile, which ignores the effect of edge heat sinks, and (2) dome-shaped-temperature profile, which approximates the actual surface temperature distribution associated with the existence of edge heat sinks. The finite-element method was used to calculate the deformation field and thermal stress distributions in the face sheets and core of the sandwich panel. The detailed thermal stress distributions in the sandwich panel are presented, and critical stress regions are identified. The study shows how the magnitudes of those critical stresses and their locations change with different heating and edge conditions. This technical report presents comprehensive, three-dimensional graphical displays of thermal stress distributions in every part of a titanium honeycomb-core sandwich panel subjected to hypersonic heating on one side. The plots offer quick visualization of the structural response of the panel and are very useful for hot structures designers to identify the critical stress regions.

Ko, William L.↗