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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.
Flexible ablators were conceived in 2009 to meet the technology pull for large, human Mars Exploration Class, 23 m diameter hypersonic inflatable aerodynamic decelerators. As described elsewhere, they have been recently undergoing initial technical readiness (TRL) advancement by NASA. The performance limits of flexible ablators in terms of maximum heat rates, pressure and shear remain to be defined. Further, it is hoped that this emerging technology will vastly expand the capability of future NASA missions involving atmospheric entry systems. This paper considers four topics of relevance to flexible ablators: (1) Their potential applications to near/far term human and robotic missions (2) Brief consideration of the balance between heat shield diameter, flexible ablator performance limits, entry vehicle controllability and aft-body shear layer impingement of interest to designers of very large entry vehicles, (3) The approach for developing bonding processes of flexible ablators for use on rigid entry bodies and (4) Design of large arcjet test articles that will enable the testing of flexible ablators in flight-like, combined environments (heat flux, pressure, shear and structural tensile loading). Based on a review of thermal protection system performance requirements for future entry vehicles, it is concluded that flexible ablators have broad applications to conventional, rigid entry body systems and are enabling to large deployable (both inflatable and mechanical) heat shields. Because of the game-changing nature of flexible ablators, it appears that NASA's Office of the Chief Technologist (OCT) will fund a focused, 3-year TRL advancement of the new materials capable of performance in heat fluxes in the range of 200-600 W/sq. cm. This support will enable the manufacture and use of the large-scale arcjet test designs that will be a key element of this OCT funded activity.
A model for simulating nonequilibrium radiation from Mars entry shock layers is presented. A new chemical kinetic rate model is developed that provides good agreement with recent EAST and X2 shock tube radiation measurements. This model includes a CO dissociation rate that is a factor of 13 larger than the rate used widely in previous models. Uncertainties in the proposed rates are assessed along with uncertainties in translational-vibrational relaxation modeling parameters. The stagnation point radiative flux uncertainty due to these flowfield modeling parameter uncertainties is computed to vary from 50 to 200% for a range of free-stream conditions, with densities ranging from 5e-5 to 5e-4 kg/m3 and velocities ranging from of 6.3 to 7.7 km/s. These conditions cover the range of anticipated peak radiative heating conditions for proposed hypersonic inflatable aerodynamic decelerators (HIADs). Modeling parameters for the radiative spectrum are compiled along with a non-Boltzmann rate model for the dominant radiating molecules, CO, CN, and C2. A method for treating non-local absorption in the non-Boltzmann model is developed, which is shown to result in up to a 50% increase in the radiative flux through absorption by the CO 4th Positive band. The sensitivity of the radiative flux to the radiation modeling parameters is presented and the uncertainty for each parameter is assessed. The stagnation point radiative flux uncertainty due to these radiation modeling parameter uncertainties is computed to vary from 18 to 167% for the considered range of free-stream conditions. The total radiative flux uncertainty is computed as the root sum square of the flowfield and radiation parametric uncertainties, which results in total uncertainties ranging from 50 to 260%. The main contributors to these significant uncertainties are the CO dissociation rate and the CO heavy-particle excitation rates. Applying the baseline flowfield and radiation models developed in this work, the radiative heating for the Mars Pathfinder probe is predicted to be nearly 20 W/cm2. In contrast to previous studies, this value is shown to be significant relative to the convective heating.
Aerogels are potential materials for aerospace applications due to their lower thermal conductivity, lighter weight, and low dielectric constant. However, silica aerogels are restricted due to their inherent fragility, hygroscopic nature, and poor mechanical properties, especially in extreme aerospace environments. In order to fit the needs of aerospace applications, developing new thermal insulation materials that are flexible, and moisture resistant is needed. To this end, we fabricated a series of polyimide aerogels crosslinked with different poly(maleic anhydride-alt-alkylene)s as seen in Scheme 1. The polyimide oligomers were made with 3,3,4,4-biphenyltetracarboxylic dianhydride (BPDA), and different diamines or diamine combinations. The resulting aerogels have low density (0.06 gcm3 to 0.16 gcm3) and high surface area (240-440 m2g). The effect of the different backbone structures on density, shrinkage, porosity, surface area, mechanical properties, moisture resistance and thermal properties will be discussed. These novel polyalkylene-imide aerogels may be potential candidates for applications such as space suit insulation for planetary surface missions, insulation for inflatable structures for habitats, inflatable aerodynamic decelerators for entry, descent and landing (EDL) operations, and cryotank insulation for advance space propulsion systems. Scheme 1. Network of polyimide aerogels crosslinked with deifferent poly(maleic anhydride).
The Inflatable Reentry Vehicle Experiment 3 (IRVE-3) launched July 23, 2012, from NASA Wallops Flight Facility and successfully performed its mission, demonstrating both the survivability of a hypersonic inflatable aerodynamic decelerator in the reentry heating environment and the effect of an offset center of gravity on the aeroshell's flight L/D. The reentry vehicle separated from the launch vehicle, released and inflated its aeroshell, reoriented for atmospheric entry, and mechanically shifted its center of gravity before reaching atmospheric interface. Performance data from the entire mission was telemetered to the ground for analysis. This paper discusses the IRVE-3 mission scenario, reentry vehicle design, and as-flown performance of the attitude control system in the different phases of the mission.
One gap in current pressure-measurement technology is a high-spatial-resolution method for accurately measuring pressures on spatially and temporally varying wind-tunnel models such as Inflatable Aerodynamic Decelerators (IADs), parachutes, and sails. Conventional pressure taps only provide sparse measurements at discrete points and are difficult to integrate with the model structure without altering structural properties. Pressure Sensitive Paint (PSP) provides pressure measurements with high spatial resolution, but its use has been limited to rigid or semi-rigid models. Extending the use of PSP from rigid surfaces to flexible surfaces would allow direct, high-spatial-resolution measurements of the unsteady surface pressure distribution. Once developed, this new capability will be combined with existing stereo photogrammetry methods to simultaneously measure the shape of a dynamically deforming model in a wind tunnel. Presented here are the results and methodology for using PSP on flexible surfaces.
The Terrestrial HIAD Orbital Reentry (THOR) is planned for flight in 2016 as a secondary payload on an Orbital Sciences commercial resupply mission to the International Space Station. THOR will launch with its Hypersonic Inflatable Aerodynamic Decelerator (HIAD) stowed as a small cylinder between the second stage motor and the launch vehicle fairing. Once the Cygnus cargo vehicle has separated from the second stage, THOR will likewise separate, autonomously re-orient itself, perform a deorbit burn, then inflate the HIAD to a 3.5m diameter cone before atmospheric interface. THOR is a follow-on mission to the IRVE-3 flight test of 2012. The high energy of orbital reentry will allow THOR to demonstrate the performance of its improved, second-generation inflatable structure and flexible TPS materials, in a more energetic entry environment than previous suborbital test flights.This paper discusses the sequence of events planned to occur as part of the THOR mission. Specific topics will include the THOR mission concept, reentry vehicle design for the expected flight environment, the on-board sensors that will allow quantification of vehicle performance, and how we intend to retrieve the flight data from a reentry vehicle splashing down in international waters.
Conical shell theory and piston theory aerodynamics are used to study the aeroelastic stability of the thermal protection system (TPS) on the NASA Hypersonic Inflatable Aerodynamic Decelerator (HIAD). Structural models of the TPS consist of single or multiple orthotropic conical shell systems resting on several circumferential linear elastic supports. The shells in each model may have pinned (simply-supported) or elastically-supported edges. The Lagrangian is formulated in terms of the generalized coordinates for all displacements and the Rayleigh-Ritz method is used to derive the equations of motion. The natural modes of vibration and aeroelastic stability boundaries are found by calculating the eigenvalues and eigenvectors of a large coefficient matrix. When the in-flight configuration of the TPS is approximated as a single shell without elastic supports, asymmetric flutter in many circumferential waves is observed. When the elastic supports are included, the shell flutters symmetrically in zero circumferential waves. Structural damping is found to be important in this case. Aeroelastic models that consider the individual TPS layers as separate shells tend to flutter asymmetrically at high dynamic pressures relative to the single shell models. Several parameter studies also examine the effects of tension, orthotropicity, and elastic support stiffness.
As aerospace applications become ever more demanding, novel insulation materials with lower thermal conductivity, lighter weight and higher use temperature are required to fit the aerospace application needs. Having nanopores and high porosity, aerogels are superior thermal insulators, among other things. The use of silica aerogels in general is quite restricted due to their inherent fragility, hygroscopic nature, and poor mechanical properties, especially in extereme aerospace environments. Our research goal is to develop aerogels with better mechanical and environmental stability for a variety of aeronautic and space applications including space suit insulation for planetary surface missions, insulation for inflatable structures for habitats, inflatable aerodynamic decelerators for entry, descent and landing (EDL) operations, and cryotank insulation for advance space propulsion systems. Different type of aerogels including organic-inorganic polymer reinforced (hybrid) silica-based aerogels, polyimide aerogels and inorganic aluminosilicate aerogels have been developed and examined.
This paper discusses the current technology available to design and develop a reliable and compact instrumentation platform for parachute system data collection and command actuation. Wireless communication with a parachute canopy will be an advancement to the state of the art of parachute design, development, and testing. Embedded instrumentation of the parachute canopy will provide reefing line tension, skirt position data, parachute health monitoring, and other telemetry, further validating computer models and giving engineering insight into parachute dynamics for both Earth and Mars entry that is currently unavailable. This will allow for more robust designs which are more optimally designed in terms of structural loading, less susceptible to adverse dynamics, and may eventually pave the way to currently unattainable advanced concepts of operations. The development of this technology has dual use potential for a variety of other applications including inflatable habitats, aerodynamic decelerators, heat shields, and other high stress environments.
A trajectory design and analysis that describes aerocapture, entry, descent, and inflation of manned and unmanned High Altitude Venus Operation Concept (HAVOC) lighter-than-air missions is presented. Mission motivation, concept of operations, and notional entry vehicle designs are presented. The initial trajectory design space is analyzed and discussed before investigating specific trajectories that are deemed representative of a feasible Venus mission. Under the project assumptions, while the high-mass crewed mission will require further research into aerodynamic decelerator technology, it was determined that the unmanned robotic mission is feasible using current technology.
With the development of technology for aerospace applications, new thermal insulation materials are required to be flexible and capable of surviving high heat flux. For instance, flexible insulation is needed for inflatable aerodynamic decelerators which are used to slow spacecraft for entry, descent and landing (EDL) operations. Polyimide aerogels have low density, high porosity, high surface area, and better mechanical properties than silica aerogels and can be made into flexible thin films, thus they are potential candidates for aerospace needs. The previously reported cross-linkers such as octa(aminophenyl)silsesquioxane (OAPS) and 1,3,5-triaminophenoxybenzene (TAB) are either expensive or not commercially available. Here, we report the synthesis of a series of polyimide aerogels cross-linked using various commercially available poly(maleic anhydride)s, as seen in Figure 1. The amine end capped polyimide oligomers were made with 3,3,4,4-biphenyltetracarboxylic dianhydride (BPDA) and diamine combinations of dimethylbenzidine (DMBZ) and 4, 4-oxydianiline (ODA). The resulting aerogels have low density (0.12 gcm3 to 0.16 gcm3), high porosity (90) and high surface area (380-554 m2g). The effect of the different poly(maleic anhydride) cross-linkers and polyimide backbone structures on density, shrinkage, porosity, surface area, mechanical properties, moisture resistance and thermal properties will be discussed.
To support NASAs long term goal of landing humans on Mars, technologies which enable the landing of heavy payloads are being developed. Current entry, decent, and landing technologies are not practical for human class payloads due to geometric constraints dictated by current launch vehicle fairing limitations. Therefore, past and present technologies are now being explored to provide a mass and volume efficient solution to atmospheric entry, including Hypersonic Inflatable Aerodynamic Decelerators (HIADs). In October of 2014, a 3.7m HIAD inflatable structure with an integrated flexible thermal protection sys-tem (F-TPS) was subjected to a static load test series to verify the designs structural performance. The 3.7m HIAD structure was constructed in a 70 deg sphere-cone stacked-toroid configuration using eight inflatable tori, which were joined together using adhesives and high strength textile webbing to help distribute the loads throughout the inflatable structure. The inflatable structure was fabricated using 2nd generation structural materials that permit an increase in use temperature to 400 C+ as compared to the 250 C limitation of the 1st generation materials. In addition to the temperature benefit, these materials also offer a 40 reduction in structure mass. The 3.7m F-TPS was fabricated using high performance materials to protect the inflatable structure from heat loads that would be seen during atmospheric entry. The F-TPS was constructed of 2nd generation TPS materials increasing its heating capability from 35W sq cm to over 100W sq cm. This test article is the first stacked-torus HIAD to be fabricated and tested with a 70 deg sphere-cone. All previous stacked-torus HIADs have employed a 60o sphere-cone. To perform the static load test series, a custom test fixture was constructed. The fixture consisted of a structural tub rim with enough height to allow for dis-placement of the inflatable structure as loads were applied. The tub rim was attached to the floor to provide an airtight seal. The center body of the inflatable structure was attached to a pedestal mount as seen in Figure 1. Using an impermeable membrane seal draped over the test article, partial vacuum was pulled beneath the HIAD, resulting in a uniform static pressure load applied to the outer surface. During the test series an extensive amount of instrumentation was used to characterize deformed shape, shoulder deflection, strap loads, and cord loads as a function of structural configuration and applied static load. In this overview, the 3.7m HIAD static load test series will be discussed in detail, including the 3.7m HIAD inflatable structure and flexible TPS design, test setup and execution, and finally results and conclusions from the test series.
Over a decade of work has been conducted in the development of NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD project's second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6m, with cone angles of 60 and 70 deg. To meet NASA and commercial near term objectives, the HIAD team must scale the current technology up to 12-15m in diameter. The HIAD project's experience in scaling the technology has reached a critical juncture. Growing from a 6m to a 15m class system will introduce many new structural and logistical challenges to an already complicated manufacturing process. Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15m-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6m aeroshell (the largest HIAD built to date), a 12m aeroshell has four times the cross-sectional area, and a 15m one has over six times the area. This means that fabrication and test procedures will need to be reexamined to account for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs. There are also noteworthy benefits of scaling up the HIAD aeroshell to 15m-class system. Two complications in working with handmade textiles structures are the non-linearity of the materials and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the materials out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15m class HIAD. In this paper, the challenges and associated mitigation plans related to scaling up the HIAD stacked-torus aeroshell to a 15m class system will be discussed. In addition, the benefits of enlarging the structure will be further explored.
Landing humans on Mars will require entry, descent, and landing capability beyond the current state of the art. Nearly twenty times more delivered payload and an order of magnitude improvement in precision landing capability will be necessary. To better assess entry, descent, and landing technology options and sensitivities to future human mission design variations, a series of design studies on human-class Mars landers has been initiated. This paper describes the results of the first design study in the series of studies to be completed in 2016 and includes configuration, trajectory and subsystem design details for a lander with Hypersonic Inflatable Aerodynamic Decelerator (HIAD) entry technology. Future design activities in this series will focus on other entry technology options.
Over a decade of work has been conducted in the development of NASAs Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD projects second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6m, with cone angles of 60 and 70 deg. To meet NASA and commercial near term objectives, the HIAD team must scale the current technology up to 12-15m in diameter. The HIAD projects experience in scaling the technology has reached a critical juncture in development. Growing from a 6m to a 15m class system will introduce many...
Human-scale landers require the delivery of much heavier payloads to the surface of Mars than is possible with entry, descent, and landing (EDL) approaches used to date. A conceptual design was developed for a 10 m diameter crewed Mars lander with an entry mass of approx.75 t that could deliver approx.28 t of useful landed mass (ULM) to a zero Mars areoid, or lower, elevation. The EDL design centers upon use of a high ballistic coefficient blunt-body entry vehicle and throttled supersonic retro-propulsion (SRP). The design concept includes a 26 t Mars Ascent Vehicle (MAV) that could support a crew of 2 for approx.24 days, a crew of 3 for approx.16 days, or a crew of 4 for approx.12 days. The MAV concept is for a fully-fueled single-stage vehicle that utilizes a single pump-fed 250 kN engine using Mono-Methyl Hydrazine (MMH) and Mixed Oxides of Nitrogen (MON-25) propellants that would deliver the crew to a low Mars orbit (LMO) at the end of the surface mission. The MAV concept could potentially provide abort-to-orbit capability during much of the EDL profile in response to fault conditions and could accommodate return to orbit for cases where the MAV had no access to other Mars surface infrastructure. The design concept for the descent stage utilizes six 250 kN MMH/MON-25 engines that would have very high commonality with the MAV engine. Analysis indicates that the MAV would require approx.20 t of propellant (including residuals) and the descent stage would require approx.21 t of propellant. The addition of a 12 m diameter supersonic inflatable aerodynamic decelerator (SIAD), based on a proven flight design, was studied as an optional method to improve the ULM fraction, reducing the required descent propellant by approx.4 t.
Over a decade of work has been conducted in the development of NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD project's second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6 meters, with cone angles of 60 and 70 degrees. To meet NASA and commercial near-term objectives, the HIAD team must scale the current technology up to 12-15 meters in diameter. Therefore, the HIAD project's experience in scaling the technology has reached a critical juncture. Growing from a 6-meter to a 15-meter class system will introduce many new structural and logistical challenges to an already complicated manufacturing process. Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15-meter-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6-meter aeroshell (the largest HIAD built to date), a 12-meter aeroshell has four times the cross-sectional area, and a 15-meter one has over six times the area. This means that fabrication and test procedures will need to be reexamined to account for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs. There are also noteworthy benefits of scaling up the HIAD aeroshell to a 15m-class system. Two complications in working with handmade textile structures are the non-linearity of the material components and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the material components out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15-meter HIAD. In this presentation, a handful of the challenges and associated mitigation plans will be discussed, as well as an update on current manufacturing and testing that addressing these challenges.