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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Sustaining Thermal Protection Systems Needed for Uranus Probes

Summary: Achieving Uranus in-situ science objectives through deploying probes in the atmosphere requires thermal protection systems capable of withstanding extreme entry environments. NASA’s 3-D Woven based thermal protection systems (TPS), developed specifically to meet this challenge, are mature, efficient, and capable of withstanding such entry. These science-enabling capabilities need to be sustained, otherwise mission implementation risk may increase to the point that the mission is untenable. The heatshield technology has been developed in concert with industry, and manufacturing processes have been technology transferred. Current technology readiness does not guarantee future availability. Sustainment requires maintaining expertise within NASA as well as ensuring that proven industrial expertise and capabilities will be readily available in the future. A constant awareness and risk assessment followed by risk mitigation are required. The scientific community needs to be aware of these challenges. It needs to engage NASA to ensure these capabilities will be available when needed. As was the case with the atrophy of heritage carbon phenolic that led to developing the 3-D Woven capabilities, our vigilance is again needed to sustain these enabling TPS capabilities for Uranus and for other missions. Background: NASA invested in and developed Heatshield for Extreme Entry Environment Technology (HEEET) TPS that was matured to TRL 6 in 2019 as a tiled system with seams and gap-fillers. Manufacturing readiness included development of specialized looms, molding, and infusion processes using commercial partners. In support of the Mars Sample Return mission, a single-layer, seamless, single-piece variant referred to as 3MDCP (3-D woven Mid-Density Carbon-Phenolic) was developed and is limited to a 1.3m maximum diameter scale due to weaving width limitations of 80”. Molding techniques developed to transform a flat, 2”-thick 3-D woven preform into a sphere-cone shape prior to phenolic resin infusion has been demonstrated. A team at NASA Ames is currently working with industry to demonstrate infusion at full-scale. By 2026, 3MDCP will be at a high level of maturity in technical, manufacturing, and integration readiness as well as material characterization. HEEET and 3MDCP for Uranus Entry: Several system studies have evaluated and baselined 3-D Woven TPS for Uranus entry, both HEEET as well as 3MDCP. If the aeroshell carrying the descent probe is 1.3m or less, then 3MDCP is a very capable and the most mass-efficient choice. If the aeroshell is bigger than 1.3m diameter, then HEEET can meet the mission need as it allows for an aeroshell of any diameter. HEEET and 3MDCP are capable of Saturn in-situ science missions prioritized in the New Frontiers-5 draft Announcement of Opportunity (AO) and if Saturn is the mission of choice, there is a pathway for sustaining the capability. Capability Sustainment: Given NASA’s current budgetary constraints, the postponement of the next New Frontiers AO to no earlier than 2026 and the unknown delay in starting the UOP flagship effort point to potential gap years for the HEEET and 3MDCP capabilities. The first step in capability sustainment is to understand the risks as they emerge, assess those risks, and develop plans to mitigate them. Keeping the science community, who are interested in UOP as well as the larger Giant Planet missions, informed of the emerging challenges requires continuous risk assessment/mitigation. Without these steps, atrophy is more likely within the industrial partners with which NASA has partnered. This presentation will provide more details as well as steps NASA can take to minimize the impact to the UOP mission.

Ethiraj Venkatapathy↗
NASA NTRS2014

Woven Thermal Protection System (WTPS) a Novel Approach to Meet NASA's Most Demanding Reentry Missions

NASA's future robotic missions to Venus and outer planets, namely, Saturn, Uranus, Neptune, result in extremely high entry conditions that exceed the capabilities of current mid-density ablators (PICA or Avcoat). Therefore mission planners assume the use of a fully dense carbon phenolic heat shield similar to what was flown on Pioneer Venus and Galileo. Carbon phenolic (CP) is a robust Thermal Protection System (TPS) however its high density and thermal conductivity constrain mission planners to steep entries, high heat fluxes, pressures and short entry durations, in order for CP to be feasible from a mass perspective. The high entry conditions pose certification challenges in existing ground based test facilities. In 2012 the Game Changing Development Program in NASA's Space Technology Mission Directorate funded NASA ARC to investigate the feasibility of a Woven Thermal Protection System (WTPS) to meet the needs of NASA's most challenging entry missions. This presentation will summarize maturation of the WTPS project.

carbon phenolic↗
NASA NTRS2014

Woven Thermal Protection System (WTPS) - a Novel Approach to Meet NASA's Most Demanding Missions

NASAs future robotic missions utilizing an entry system into Venus and the outer planets, namely, Saturn, Uranus, Neptune, result in extremely high entry conditions that exceed the capabilities of state of the art low to mid density ablators such as PICA or Avcoat. Therefore mission planners typically assume the use of a fully dense carbon phenolic heat shield similar to what was flown on Pioneer Venus and Galileo. Carbon phenolic is a robust TPS material however its high density and relatively high thermal conductivity constrain mission planners to steep entries, with high heat fluxes and pressures and short entry durations, in order for CP to be feasible from a mass perspective. The high entry conditions pose challenges for certification in existing ground based test facilities and the longer-term sustainability of CP will continue to pose challenges. In 2012 the Game Changing Development Program (GCDP) in NASAs Space Technology Mission Directorate funded NASA ARC to investigate the feasibility of a Woven Thermal Protection System (WTPS) to meet the needs of NASAs most challenging entry missions. This project was highly successful demonstrating that a Woven TPS solution compares favorably to CP in performance in simulated reentry environments and provides the opportunity to manufacture graded materials that should result in overall reduced mass solutions and enable a much broader set of missions than does CP. Building off the success of the WTPS project GCDP has funded a follow on project to further mature and scale up the WTPS concept for insertion into future NASA robotic missions. The matured WTPS will address the CP concerns associated with ground based test limitations and sustainability. This presentation will discuss results from the WTPS heat-shield for extreme entry environment technology (HEEET) project

woven TPS↗
NASA NTRSDate not supplied

An Overview of Experiments and Modeling of Polysiloxane-Coated Thermal Protection Systems for Missions to Mars, Titan, and Beyond.

Phenolic Impregnated Carbon Ablator (PICA) gained heritage during the historic Stardust mission, where it successfully returned samples from a comet’s tail and has since been instrumental in delivering payloads to the surface of Mars [1-3]. Most recently, PICA enabled the safe return of samples collected from asteroid Bennu as part of the OSIRIS-REx mission. This rich legacy underscores PICA’s critical role in allowing NASA’s most ambitious exploration missions. However, the friable nature of its phenolic phase presents challenges during handling and pre-launch activities. To mitigate this issue, PICA is coated with a polysiloxane resin system, which serves to suppress particulate dispersion and thereby safeguard spacecraft components. A comprehensive understanding of the polysiloxane resin’s behavior is imperative, as it profoundly shapes the material response of PICA during atmospheric entry by influencing its thermal and oxidative stability. This influence extends to thermocouple plugs embedded within thermal protection systems. These plugs have demonstrated their significance in missions such as Mars Science Laboratory (MSL) and Mars 2020, where the MEDLI and MEDLI2 instrumentation suites delivered in-valuable insights into the performance of thermal protection systems during entry into the Martian atmosphere [4]. Looking ahead, missions such as Dragonfly, set to descend into Titan’s dense atmosphere, aim to leverage advanced sensor technologies to further refine our understanding of thermal protection response [5]. Moreover, thermocouple plugs play an essential role in validating cutting-edge material response models, such as those pioneered under NASA’s Entry Systems Modeling Project (ESM), designed, in-part, to predict the operational integrity of thermal protection systems under the extreme stresses of atmospheric entry. To achieve these modeling goals, ground-based experiments are crucial to provide the foundational data necessary for developing and refining these predictive tools. To this end, an extensive test campaign was conducted at the Hypersonic Materials Environmental Test System (HyMETS) to investigate the high-temperature behavior of the polysiloxane resin in an air environment [6]. These experiments revealed critical phenomena, including the formation of a silicon oxycarbide layer that enhances oxidation resistance, moderates surface temperatures, and alters in-depth thermal response. Building on these findings, subsequent tests were designed to simulate atmospheric entry conditions in reactive gases, such as CO2 and N2, to mimic the environments of Mars and Titan, respectively, as well as non-reactive gases representing the atmospheres of the Ice Giants (Neptune and Uranus). A heating rate dependent decomposition mechanism has been identified for the polysiloxane resin under oxidizing conditions (Fig. 1). In the initial stage, the resin and the underlying thermal protection system undergo pyrolysis, rapidly generating a thin amorphous silicon oxycarbide interwoven with carbonaceous char and residual fibers from PICA. During the second stage, the nascent oxide layer establishes a robust, oxidation-resistant thermal barrier coating, which significantly impedes heat transfer to the underlying carbonaceous char, resulting in a stagnation of the surface temperature. A key factor contributing to this thermal resistance is the low recombination efficiency of atomic oxygen (γ), which further diminishes the heat load on the material’s interior layers [7]. Moreover, as the surface temperature stagnates, the silicon oxycarbide phase separates into distinct regions of silica and free graphite. Ultimately, when the heat flux reaches a critical threshold, a third stage is triggered, leading to the breakdown of the coating through carbothermal reduction, exposing the underlying char layer. This exposure leads to a dramatic surface temperature spike, driven by highly exothermic reactions between atomic oxygen and the char layer, further accelerating material degradation. A detailed mass and heat transfer model of PICA coated with polysiloxane resin was implemented in the Porous material Analysis Toolbox based on OpenFOAM, PATO [8]. The initial stage was considered negligible in this model because the resin decomposition occurs rapidly within a thin surface layer. Instead, the coating was directly considered as an oxygen-resistant thermal barrier coating. For the second stage, the thin amorphous silicon oxycarbide was treated as a pure silica surface to simplify the thermochemical behavior. The model ac-counts for surface equilibrium processes using representative elements of the coating-environment system. For the third stage, specific boundary conditions were developed to estimate the onset and progression of the coating removal. Two-dimensional material response simulations were conducted to compare uncoated and coated PICA using boundary conditions calibrated with HyMETS data. Fig. 2 illustrates that the simulations closely align with experimental data, successfully reproducing measured temperature profiles. This work will include the latest advancements in the coating model, including the calibration of recombination of atomic oxygen at the surface during the second phase. These simulated results will be further validated against additional CO2 data points from HyMETS, reinforcing the models’ predictive capabilities. These mechanisms and their effects on thermal protection systems, including thermochemical behavior and thermocouple probe performance in extreme environments, provide crucial insights for optimizing spacecraft designs that safeguard scientific payload and ensure mission success in future planetary exploration endeavors.

Active Oxidation↗
NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials (3MDCP)

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Woven↗
NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Discrete Element Method↗
NASA NTRSDate not supplied

Thermomechanical Modeling of Woven Materials With Particle-Based, Explicit-Fiber Simulations

Fiber-based materials are extensively used to protect spacecraft during entry. Insulative fibers, often in a fiber network or woven, provide rigidity, strength, and control of material anisotropy and density. Woven thermal protection materials, such as ADEPT (Adaptable, Deployable Entry and Placement Technology), 3D-MAT (3-Dimensional Multifunctional Ablative Thermal Protection), and 3MDCP (3D Woven Mid-Density Carbon Phenolic), enable missions with stronger and denser materials for entry profiles with high shear and heat flux. Vulnerabilities to woven thermal protection materials include manufacturing-induced material property variation, and impact from micrometeoroids. Simulating woven materials under these conditions require models that can resolve hierarchal structures, thermomechanical behavior, and failure. To address this, we simulate weave thermal conduction and mechanical deformation. We simulate the full weave with a coarse-grained yarn model is presented. The model combines a validated, high-resolution single 3MDCP yarn model and phenolic resin model. Instead of modeling every fiber, each yarn ply with order 10, instead of order 1000, fibers. The discrete element bonded particle model (DEM-BPM) of fibers captures the thermal and mechanical behavior within and between fibers. We study the proportion of heat transfer and stress via the contact network, fiber bonds, and overall weave geometry.

bonded particle↗
NASA NTRS1972

Demonstration of the range over which the Langley Research Center digital computer charring ablation program (CHAP) can be used with confidence: Comparisons of CHAP predictions and test data for three ablation materials

Comparisons of ablation calculations with the charring ablation computer code and ablation test data are presented over a wide range of environmental conditions in air for three materials: low-density nylon phenolic, Avcoat 5026-39HC/G, and a filled silicon elastomer. Heat fluxes considered range from over 500 Btu/sq ft-sec to less than 50 Btu/sq ft-sec. Pressures range from 0.5 atm to .004 atm. Enthalpies range from about 2000 Btu/lb to 18000 Btu/lb. Predictions of recession, pyrolysis penetration, and thermocouple responses are considered. Recession predictions for nylon phenolic are good as steady state is approached, but strongly transient cases are underpredicted. Pyrolysis penetrations and thermocouple responses are very well predicted. Recession amounts for Avcoat and silicone elastomer are less well predicted, although high heat flux cases near steady state are fairly satisfactory. Pyrolysis penetrations and thermocouple responses are very well predicted.

Moyer, C. B.↗
NASA NTRS1972

Flight and ground tests of a very low density elastomeric ablative material

A very low density ablative material, a silicone-phenolic composite, was flight tested on a recoverable spacecraft launched by a Pacemaker vehicle system; and, in addition, it was tested in an arc heated wind tunnel at three conditions which encompassed most of the reentry heating conditions of the flight tests. The material was composed, by weight, of 71 percent phenolic spheres, 22.8 percent silicone resin, 2.2 percent catalyst, and 4 percent silica fibers. The tests were conducted to evaluate the ablator performance in both arc tunnel and flight tests and to determine the predictability of the albator performance by using computed results from an existing one-dimensional numerical analysis. The flight tested ablator experienced only moderate surface recession and retained a smooth surface except for isolated areas where the char was completely removed, probably following reentry and prior to or during recovery. Analytical results show good agreement between arc tunnel and flight test results. The thermophysical properties used in the analysis are tabulated.

Olsen, G. C.↗
NASA NTRS1972

Thermal performance of 625-kg/cu m elastomeric ablative materials on spherically blunted 0.44-radian cones

Spherically blunted 0.44-radian (25 deg) half-angle conical models coated with elastomeric ablative materials were tested in supersonic arc-heated wind tunnels to evaluate performance of the ablators over a range of conditions typical of lifting entry. Four test conditions were combinations of stagnation point-heat transfer rates of 2.3 and 4.5 MW/m2 and stagnation pressures of 20 and 2kN/m2. Afterbody values of heat transfer rate and pressure were 0.05 to 0.20 of stagnation point values. Stagnation enthalpy varied from 4.4 to 25 MJ/kg (1900 to 11000 Btu/lbm) and free-stream Mach number was in a range from 3.5 to 4. Ablative materials retained the spherical nose shape throughout tests at the lower heat transfer level, but receded, assuming a flattened nose shape, during tests at the high heat transfer level. The residue layer that formed on the conical after-body was weak, friable, and extensively cracked. The reference ablative material, which contained phenolic microspheres, generally retained the conical shape on the model afterbody. However, a modified ablator, in which phenolic microspheres were replaced with silica microspheres, deformed and separated from the undegraded material, and thereby produced a very uneven surface. Substrate temperatures and ablator recession were in good agreement with values computed by a numerical analysis.

Champman, A. J.↗
NASA NTRS1972

Development of seal ring carbon-graphite materials (tasks 5, 6, and 7)

Carbon-graphite seal ring bodies for operation at air temperatures to 1300 F(704 C) were manufactured from three select formulations. Mechanical and thermal properties, porosities, and oxidation rates were measured. The results have shown that: (1) Major property improvements anticipated from the screening studies were not realized because of processing problems associated with the scale-up in material size and probable deterioration of a phenolic resin binder; (2) the mechanical properties of a phenolic resin-bonded, carbon-graphite material can be improved by applying high pressure during carbonization; and (3) the textile form of graphite fiber used as the minor filler component in a carbon-graphite material can beneficially affect mechanical properties.

Fechter, N. J.↗
NASA NTRS1973

Effects of material composition on the ablation performance of low density elastomeric ablators

The ablation performance of materials composed of various concentrations of nylon, hollow silica spheres, hollow phenolic spheres, and four elastomeric resins was determined. Both blunt-body and flat-panel specimens were used, the cold-wall heating-rate ranges being 0.11 to 0.8 MW/sq m, respectively. The corresponding surface pressure ranges for these tests were 0.017 to 0.037 atmosphere and 0.004 to 0.005 atmosphere. Some of the results show that (1) the addition of nylon significantly improved the ablation performance, but the nylon was not compatible with one resin system; (2) panel and blunt-body specimen data do not show the same effect of phenolic sphere content on ablation effectiveness; and (3) there appears to be an optimum concentration of hollow silica spheres for good ablation performance. The composition of an efficient, nonproprietary ablator for lifting body application is identified and the ablation performance of this ablator is compared with the performance of three commercially available materials.

Tompkins, S. S.↗
NASA NTRS1974

The effect of ablation injection on radiative and convective heating

A viscous shock-layer analysis is for calculating high energy equilibrium flow fields about blunt axisymmetric bodies is applied to the problem of massive ablation injection with radiation transport. A nongray radiation model is used that accounts for both line and continuum radiation. The solution method is direct and provides both stagnation and downstream solutions. Results for shock heated air show that phenolic-nylon injection is substantially more effective in reducing the wall radiant flux than air injection. Also, for large included body angles, the wall radiative flux and the coupled phenolic-nylon injection rate do not continue to decrease with increasing distance downstream.

Moss, J. N.↗
NASA NTRS1975

Improvement in oxidation resistance of the leading edge thermal protection for a space shuttle

To improve the oxidation resistance of a carbon-carbon composite, impregnations were performed using pitches, polyfurfuryl alcohols, and phenolic resins, including a silicon-doped phenolic resin. Oxidation resistance and strength increased for all of the composites as the impregnant-carbon residue increased. The properties of the composites impregnated with the nonsilicon-bearing resins were nearly identical and depended only on the amount of impregnant residue present. However, for equivalent residue concentrations, composites produced with the silicon-bearing resin gave higher strengths and at least 100% better oxidation resistance than was observed for the other composites or for a prototype control material.

Williams, J. M.↗
NASA NTRS1976

Polymeric foams stable at high temperatures

Crosslinked poly(N-arylenebenzimidazoles) are stable up to 370 C. Polymers are made by mixing appropriate stoichiometric amounts of tetramine and aromatic dicarboxylic acid anhydride with phenol or alkyl-substituted phenol.

Riccitiello, S. R.↗