Engineering topics

Milos, Frank S.

Publications and source records attributed to Milos, Frank S..

At least 19 records

NASA NTRS2018

Sizing and Margin Methodology for Dual-Layer Thermal Protection Systems

This presentation introduces a new sizing and margin methodology for dual-layer Thermal Protection Systems (TPS). The methodology has been tailored for application to a dual-layer 3D-woven TPS called Heat-shield for Extreme Entry Environments Technology (HEEET). Sizing is performed for a reference Saturn probe mission to show how uncertainties in trajectory, aerothermal modelling and TPS response impact the sizing of each layer.

Sizing↗

NASA NTRS2018

Aerothermal Design of a Common Probe for Multiple Planetary Destinations

Estimate the mass of the Thermal Protection System (TPS) for a single design construct of an atmospheric entry probe with a rigid aeroshell, which could be used at five destinations, i.e. Venus, Saturn, Uranus, Neptune, and perhaps, Jupiter. The entry mass of the probe is 400 kg with a ballistic coefficient of 216 kg/m2. Process: The 3DoF trajectory simulation program Traj, coupled with the TPS response program FIAT was used for simulation and design. The assumed atmospheric models were VIRA (Venus-GRAM) for Venus, the Julianne Moses' model for Saturn, a NASA Ames engineering model for Uranus, Neptune-GRAM for Neptune, and Galileo Probe (Al Seiff's) result for Jupiter.

Allen, Gary A., Jr.↗

NASA NTRS2018

Overview of Heatshield for Extreme Entry Environment Technology (HEEET)

The Heatshield for Extreme Entry Environment Technology (HEEET) projects objective is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. The scope of the project, status of which will be discussed, encompasses development of manufacturing and integration processes, fabrication of a prototype 1m diameter engineering test unit (ETU) that will undergo a series of structural tests, characterizing material aerothermal performance including development of a material response model, and structural testing and analysis to develop tools to support design and establish system capability.

Driver, David M.↗

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 NTRS2013

Effects of Nonequilibrium Chemistry and Darcy-Forchheimer Pyrolysis Flow for Charring Ablator

The fully implicit ablation and thermal response code simulates pyrolysis and ablation of thermal protection materials and systems. The governing equations, which include energy conservation, a three-component decomposition model, and a surface energy balance, are solved with a moving grid.This work describes new modeling capabilities that are added to a special version of code. These capabilities include a time-dependent pyrolysis gas flow momentum equation with Darcy-Forchheimer terms and pyrolysis gas species conservation equations with finite rate homogeneous chemical reactions. The total energy conservation equation is also enhanced for consistency with these new additions. Two groups of parametric studies of the phenolic impregnated carbon ablator are performed. In the first group, an Orion flight environment for a proposed lunar-return trajectory is considered. In the second group, various test conditions for arcjet models are examined. The central focus of these parametric studies is to understand the effect of pyrolysis gas momentum transfer on material in-depth thermal responses with finite-rate, equilibrium, or frozen homogeneous gas chemistry. Results indicate that the presence of chemical nonequilibrium pyrolysis gas flow does not significantly alter the in-depth thermal response performance predicted using the chemical equilibrium gas model.

Chen, Yih-Kanq↗

NASA NTRS2012

Nonequilibrium Ablation of Phenolic Impregnated Carbon Ablator

In previous work, an equilibrium ablation and thermal response model for Phenolic Impregnated Carbon Ablator was developed. In general, over a wide range of test conditions, model predictions compared well with arcjet data for surface recession, surface temperature, in-depth temperature at multiple thermocouples, and char depth. In this work, additional arcjet tests were conducted at stagnation conditions down to 40 W/sq cm and 1.6 kPa. The new data suggest that nonequilibrium effects become important for ablation predictions at heat flux or pressure below about 80 W/sq cm or 10 kPa, respectively. Modifications to the ablation model to account for nonequilibrium effects are investigated. Predictions of the equilibrium and nonequilibrium models are compared with the arcjet data.

Milos, Frank S.↗

NASA NTRS2012

Arcjet Testing and Thermal Model Development for Multilayer Felt Reusable Surface Insulation

Felt Reusable Surface Insulation was used extensively on leeward external surfaces of the Shuttle Orbiter, where the material is reusable for temperatures up to 670 K. For application on leeward surfaces of the Orion Multi-Purpose Crew Vehicle, where predicted temperatures reach 1620 K, the material functions as a pyrolyzing conformal ablator. An arcjet test series was conducted to assess the performance of multilayer Felt Reusable Surface Insulation at high temperatures, and a thermal-response, pyrolysis, and ablation model was developed. Model predictions compare favorably with the arcjet test data

Milos, Frank S.↗

NASA NTRS2011

Effects of Non-Equilibrium Chemistry and Darcy-Forchheimer Flow of Pyrolysis Gas for a Charring Ablator

The Fully Implicit Ablation and Thermal Response code, FIAT, simulates pyrolysis and ablation of thermal protection materials and systems. The governing equations, which include energy conservation, a three-component decomposition model, and a surface energy balance, are solved with a moving grid. This work describes new modeling capabilities that are added to a special version of FIAT. These capabilities include a time-dependent pyrolysis gas flow momentum equation with Darcy-Forchheimer terms and pyrolysis gas species conservation equations with finite-rate homogeneous chemical reactions. The total energy conservation equation is also enhanced for consistency with these new additions. Parametric studies are performed using this enhanced version of FIAT. Two groups of analyses of Phenolic Impregnated Carbon Ablator (PICA) are presented. In the first group, an Orion flight environment for a proposed Lunar-return trajectory is considered. In the second group, various test conditions for arcjet models are examined. The central focus of these parametric studies is to understand the effect of pyrolysis gas momentum transfer on PICA material in-depth thermal responses with finite-rate, equilibrium, or frozen homogeneous gas chemistry. Results are presented, discussed, and compared with those predicted by the baseline PICA/FIAT ablation and thermal response model developed by the Orion Thermal Protection System Advanced Development Project.

Ablation↗

NASA NTRS2011

Comparison of Ablation Predictions for Carbonaceous Materials Using CEA and JANAF-Based Species Thermodynamics

In most previous work at NASA Ames Research Center, ablation predictions for carbonaceous materials were obtained using a species thermodynamics database developed by Aerotherm Corporation. This database is derived mostly from the JANAF thermochemical tables. However, the CEA thermodynamics database, also used by NASA, is considered more up to date. In this work, the FIAT code was modified to use CEA-based curve fits for species thermodynamics, then analyses using both the JANAF and CEA thermodynamics were performed for carbon and carbon phenolic materials over a range of test conditions. The ablation predictions are comparable at lower heat fluxes where the dominant mechanism is carbon oxidation. However, the predictions begin to diverge in the sublimation regime, with the CEA model predicting lower recession. The disagreement is more significant for carbon phenolic than for carbon, and this difference is attributed to hydrocarbon species that may contribute to the ablation rate.

Milos, Frank S.↗

NASA NTRS2010

Validation of a Three-Dimensional Ablation and Thermal Response Simulation Code

The 3dFIAT code simulates pyrolysis, ablation, and shape change of thermal protection materials and systems in three dimensions. The governing equations, which include energy conservation, a three-component decomposition model, and a surface energy balance, are solved with a moving grid system to simulate the shape change due to surface recession. This work is the first part of a code validation study for new capabilities that were added to 3dFIAT. These expanded capabilities include a multi-block moving grid system and an orthotropic thermal conductivity model. This paper focuses on conditions with minimal shape change in which the fluid/solid coupling is not necessary. Two groups of test cases of 3dFIAT analyses of Phenolic Impregnated Carbon Ablator in an arc-jet are presented. In the first group, axisymmetric iso-q shaped models are studied to check the accuracy of three-dimensional multi-block grid system. In the second group, similar models with various through-the-thickness conductivity directions are examined. In this group, the material thermal response is three-dimensional, because of the carbon fiber orientation. Predictions from 3dFIAT are presented and compared with arcjet test data. The 3dFIAT predictions agree very well with thermocouple data for both groups of test cases.

Chen, Yih-Kanq↗

NASA NTRS2010

Computational Analysis of Arc-Jet Wedge Tests Including Ablation and Shape Change

Coupled fluid-material response analyses of arc-jet wedge ablation tests conducted in a NASA Ames arc-jet facility are considered. These tests were conducted using blunt wedge models placed in a free jet downstream of the 6-inch diameter conical nozzle in the Ames 60-MW Interaction Heating Facility. The fluid analysis includes computational Navier-Stokes simulations of the nonequilibrium flowfield in the facility nozzle and test box as well as the flowfield over the models. The material response analysis includes simulation of two-dimensional surface ablation and internal heat conduction, thermal decomposition, and pyrolysis gas flow. For ablating test articles undergoing shape change, the material response and fluid analyses are coupled in order to calculate the time dependent surface heating and pressure distributions that result from shape change. The ablating material used in these arc-jet tests was Phenolic Impregnated Carbon Ablator. Effects of the test article shape change on fluid and material response simulations are demonstrated, and computational predictions of surface recession, shape change, and in-depth temperatures are compared with the experimental measurements.

Goekcen, Tahir↗

NASA NTRS2010

Ablation, Thermal Response, and Chemistry Program for Analysis of Thermal Protection Systems

In previous work, the authors documented the Multicomponent Ablation Thermochemistry (MAT) and Fully Implicit Ablation and Thermal response (FIAT) programs. In this work, key features from MAT and FIAT were combined to create the new Fully Implicit Ablation, Thermal response, and Chemistry (FIATC) program. FIATC is fully compatible with FIAT (version 2.5) but has expanded capabilities to compute the multispecies surface chemistry and ablation rate as part of the surface energy balance. This new methodology eliminates B' tables, provides blown species fractions as a function of time, and enables calculations that would otherwise be impractical (e.g. 4+ dimensional tables) such as pyrolysis and ablation with kinetic rates or unequal diffusion coefficients. Equations and solution procedures are presented, then representative calculations of equilibrium and finite-rate ablation in flight and ground-test environments are discussed.

Milos, Frank S.↗

NASA NTRS2009

Validation of PICA Ablation and Thermal-Response Model at Low Heat Flux

Phenolic Impregnated Carbon Ablator (PICA) was the forebody heatshield material on the Stardust sample-return capsule and is also a primary candidate material for the Mars Science Lander (MSL), the Orion Crew Module, and the SpaceX Dragon vehicle. As part of the heatshield qualification for Orion, physical and thermal properties of virgin and charred PICA were measured, and an ablation and thermal response model was developed. We validated the model by comparing it with recession and temperature data from stagnation arcjet tests conducted over a wide range of stagnation heat flux of 107 to 1102 W/sq cm. The effect of orthotropic thermal conductivity was evident in the thermal response of the arcjet models. In general, model predictions compared well with the data; however, the uncertainty of the recession prediction was greatest for heat fluxes below 200 W/sq cm. More recent MSL testing focused on the low heat flux regime of 45 to 250 W/sq cm. The new results confirm the recession uncertainty, especially for pressures below 6 kPa. In this work we focus on improving the model predictions for MSL and Orion tests below 250 W/sq cm.

Milos, Frank S.↗

NASA NTRS2006

Lightweight Ablative and Ceramic Thermal Protection System Materials for NASA Exploration Systems Vehicles

As a collaborative effort among NASA Centers, the "Lightweight Nonmetallic Thermal Protection Materials Technology" Project was set up to assist mission/vehicle design trade studies, to support risk reduction in thermal protection system (TPS) material selections, to facilitate vehicle mass optimization, and to aid development of human-rated TPS qualification and certification plans. Missions performing aerocapture, aerobraking, or direct aeroentry rely on advanced heatshields that allow reductions in spacecraft mass by minimizing propellant requirements. Information will be presented on candidate materials for such reentry approaches and on screening tests conducted (material property and space environmental effects tests) to evaluate viable candidates. Seventeen materials, in three classes (ablatives, tiles, and ceramic matrix composites), were studied. In additional to physical, mechanical, and thermal property tests, high heat flux laser tests and simulated-reentry oxidation tests were performed. Space environmental effects testing, which included exposures to electrons, atomic oxygen, and hypervelocity impacts, was also conducted.

Valentine, Peter G.↗

NASA NTRS2005

Validation of Afterbody Aeroheating Predictions for Planetary Probes: Status and Future Work

A review of the relevant flight conditions and physical models for planetary probe afterbody aeroheating calculations is given. Readily available sources of afterbody flight data and published attempts to computationally simulate those flights are summarized. A current status of the application of turbulence models to afterbody flows is presented. Finally, recommendations for additional analysis and testing that would reduce our uncertainties in our ability to accurately predict base heating levels are given.

Wright, Michael J.↗

NASA NTRS2005

Lightweight Nonmetallic Thermal Protection Materials Technology

To fulfill President George W. Bush's "Vision for Space Exploration" (2004) - successful human and robotic missions to and from other solar system bodies in order to explore their atmospheres and surfaces - the National Aeronautics and Space Administration (NASA) must reduce the trip time, cost, and vehicle weight so that the payload and scientific experiments' capabilities can be maximized. The new project described in this paper will generate thermal protection system (TPS) product that will enable greater fidelity in mission/vehicle design trade studies, support risk reduction for material selections, assist in the optimization of vehicle weights, and provide materials and processes templates for use in the development of human-rated TPS qualification and certification plans.

Valentine, Peter G.↗

NASA NTRS2005

Thermal Protection Materials Technology for NASA's Exploration Systems Mission Directorate

To fulfill the President s Vision for Space Exploration - successful human and robotic missions between the Earth and other solar system bodies in order to explore their atmospheres and surfaces - NASA must reduce trip time, cost, and vehicle weight so that payload and scientific experiment capabilities are maximized. As a collaboration among NASA Centers, this project will generate products that will enable greater fidelity in mission/vehicle design trade studies, support risk reduction for material selections, assist in optimization of vehicle weights, and provide the material and process templates for development of human-rated qualification and certification Thermal Protection System (TPS) plans. Missions performing aerocapture, aerobraking, or direct aeroentry rely on technologies that reduce vehicle weight by minimizing the need for propellant. These missions use the destination planet s atmosphere to slow the spacecraft. Such mission profiles induce heating environments on the spacecraft that demand thermal protection heatshields. This program offers NASA essential advanced thermal management technologies needed to develop new lightweight nonmetallic TPS materials for critical thermal protection heatshields for future spacecraft. Discussion of this new program (a December 2004 new start) will include both initial progress made and a presentation of the work to be preformed over the four-year life of the program. Additionally, the relevant missions and environments expected for Exploration Systems vehicles will be presented, along with discussion of the candidate materials to be considered and of the types of testing to be performed (material property tests, space environmental effects tests, and Earth and Mars gases arc jet tests).

Valentine, Peter G.↗

NASA NTRS2003

Finite-Rate Ablation Boundary Conditions for Carbon-Phenolic Heat-Shield

A formulation of finite-rate ablation surface boundary conditions, including oxidation, nitridation, and sublimation of carbonaceous material with pyrolysis gas injection, has been developed based on surface species mass conservation. These surface boundary conditions are discretized and integrated with a Navier-Stokes solver. This numerical procedure can predict aerothermal heating, chemical species concentration, and carbonaceous material ablation rate over the heatshield surface of re-entry space vehicles. In this study, the gas-gas and gas-surface interactions are established for air flow over a carbon-phenolic heatshield. Two finite-rate gas-surface interaction models are considered in the present study. The first model is based on the work of Park, and the second model includes the kinetics suggested by Zhluktov and Abe. Nineteen gas phase chemical reactions and four gas-surface interactions are considered in the present model. There is a total of fourteen gas phase chemical species, including five species for air and nine species for ablation products. Three test cases are studied in this paper. The first case is a graphite test model in the arc-jet stream; the second is a light weight Phenolic Impregnated Carbon Ablator at the Stardust re-entry peak heating conditions, and the third is a fully dense carbon-phenolic heatshield at the peak heating point of a proposed Mars Sample Return Earth Entry Vehicle. Predictions based on both finite-rate gas- surface interaction models are compared with those obtained using B' tables, which were created based on the chemical equilibrium assumption. Stagnation point convective heat fluxes predicted using Park's finite-rate model are far below those obtained from chemical equilibrium B' tables and Zhluktov's model. Recession predictions from Zhluktov's model are generally lower than those obtained from Park's model and chemical equilibrium B' tables. The effect of species mass diffusion on predicted ablation rate is also examined.

Chen, Y.-K.↗