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NASA NTRS1978

Carbonaceous materials subjected to extreme heating - A comparison of numerical simulation and experiments

The ablation of carbonaceous materials in a hydrogen-helium stream has been simulated using a charring materials ablator computer code. These results are compared with the first ablation data to be obtained from the Ames-NASA Giant Planet Pilot Facility. Test stream diagnostics and ablation effects on convective and radiative heat transfer are discussed since these parameters constitute important input data to the numerical simulation. Graphite ablation was predicted to within 10 to 20%, and carbon-phenolic somewhat less accurately.

Davy, W. C.↗

NASA NTRSDate not supplied

An Overview of Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Capabilities, Upgrades, and Overlaps in Advanced Material Testing Areas

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) was designed to perform non-nuclear testing of nuclear thermal rocket (NTR) fuel elements and materials. NTREES can simulate the thermal hydraulic environment within the reactor of an NTR and has been leveraged to provide data on the thermochemical, thermomechanical and thermohydraulic performance of components and materials. Active upgrades to the NTREES facility include installing a DC power supply for DC powered joule heating, a supply gas chiller for a cryogenically cool gas supply, gas pre-heaters with sample holders for testing samples too small to be inductively heated by bathing them in hot gas, and a high temperature digital image correlation (DIC) capability for measuring high temperature strains real time. In addition to NTR testing, given the commonality of high enthalpy flow environments between the reactor of an NTP engine and the aerothermal heating of high-speed flight, the unique capabilities of NTREES to provide high temperature gas flows at high pressure without combustion or electrode spallation byproducts may lend itself to additional usage of the facility beyond the original intent.

Michael P Schoenfeld↗

NASA NTRS1977

The Viking X ray fluorescence experiment - Sampling strategies and laboratory simulations

Ten samples of Mars regolith material (six on Viking Lander 1 and four on Viking Lander 2) have been delivered to the X ray fluorescence spectrometers as of March 31, 1977. An additional six samples at least are planned for acquisition in the remaining Extended Mission (to January 1979) for each lander. All samples acquired are Martian fines from the near surface (less than 6-cm depth) of the landing sites except the latest on Viking Lander 1, which is fine material from the bottom of a trench dug to a depth of 25 cm. Several attempts on each lander to acquire fresh rock material (in pebble sizes) for analysis have yielded only cemented surface crustal material (duricrust). Laboratory simulation and experimentation are required both for mission planning of sampling and for interpretation of data returned from Mars. This paper is concerned with the rationale for sample site selections, surface sampler operations, and the supportive laboratory studies needed to interpret X ray results from Mars.

Baird, A. K.↗

NASA NTRS1981

Materials characterization study of conductive flexible second surface mirrors

The status of prequalification and qualification work on conductive flexible second surface mirrors is described. The basic material is FEP Teflon witn either aluminium or silver vacuum deposited reflectors. The top layer has been made conductive by deposition of layer of a indium oxide. The results of a prequalification program comprised of decontamination, humidity, thermal cycling, thermal shock and vibration tests are presented. Thermo-optical and electrical properties. The results of a prequalification program comprised of decontamination, humidity, thermal cycling, thermal shock and vibration tests are presented. Thermo-optical and electrical properties, the electrostatic behavior of the materials under simulated substorm environment and electrical conductivity at low temperatures are characterized. The effects of simulated ultra violet and particles irradiation on electrical and thermo-optical properties of the materials are also presented.

Levadou, F.↗

NASA NTRS2009

Electromagnetic Cavity Effects from Transmitters Inside a Launch Vehicle Fairing

This paper provides insight into the difficult analytical issue for launch vehicles and spacecraft that has applicability outside of the launch industry. Radiation from spacecraft or launch vehicle antennas located within enclosures in the launch vehicle generates an electromagnetic environment that is difficult to accurately predict. This paper discusses the test results of power levels produced by a transmitter within a representative scaled vehicle fairing model and provides preliminary modeling results at the low end of the frequency test range using a commercial tool. Initially, the walls of the fairing are aluminum and later, layered with materials to simulate acoustic blanketing structures that are typical in payload fairings. The effects of these blanketing materials on the power levels within the fairing are examined.

Trout, Dawn↗

NASA NTRS2009

Electromagnetic Cavity Effects from Transmitters Inside a Launch Vehicle Fairing

Trout, Dawn H.↗

NASA NTRS1986

Assessment of space environment induced microdamage in toughened composite materials

The effects of simulated space environments on the microdamage in a series of commercially available toughened matrix composite systems was determined. Low-earth orbit (LEO) exposures were simulated by thermal cycling; geosynchronous orbit (GEO) exposures were simulated by electron irradiation plus thermal cycling. Material response was characterized by assessing the induced microcracking and its influence on chemical and mechanical property changes. All materials, including several advanced, tough thermoplastics microcracked when exposed to the simulated LEO environment except a 177 C cured single phase toughened epoxy composite. The GEO simulated environment produced microdamage in all materials. The results suggest that increased matrix toughness may not be the overriding factor leading to improved durability in the space environment.

Sykes, George F.↗

NASA NTRS1971

A progress report - Induction plasma simulation of the GCNR.

Significant progress has been made in the design, construction and operation of induction coupled devices which simulate the open cycle Gas Core Nuclear Rocket. These devices incorporate solid feed of the plasma forming material (uranium and uranium simulating materials), permeable walls, seeding of the propellant, and transpiration cooled, choked flow nozzles. Operating parameters and performance data of devices employing these design features are discussed. A uranium plasma experiment is included. In addition, operating data of several devices which compare theoretical and actual performance at a variety of powers, pressures, frequencies, and sizes are discussed.

Vogel, C. E.↗

NASA NTRS1989

Tissue simulating gel for medical research

A tissue simulating gel and a method for preparing the tissue simulating gel are disclosed. The tissue simulating gel is prepared by a process using water, gelatin, ethylene gylcol, and a cross-linking agent. In order to closely approximate the characteristics of the type of tissue being simulated, other material has been added to change the electrical, sound conducting, and wave scattering properties of the tissue simulating gel. The result of the entire process is a formulation that will not melt at the elevated temperatures involved in hyperthermia medical research. Furthermore, the tissue simulating gel will not support mold or bacterial growth, is of a sufficient mechanical strength to maintain a desired shape without a supporting shell, and is non-hardening and non-drying. Substances were injected into the tissue simulating gel prior to the setting-up thereof just as they could be injected into actual tissue, and the tissue simulating gel is translucent so as to permit visual inspection of its interior. A polyurethane spray often used for coating circuit boards can be applied to the surface of the tissue simulating gel to give a texture similar to human skin, making the tissue simulating gel easier to handle and contributing to its longevity.

Companion, John A.↗

NASA NTRS1991

Tissue simulating gel for medical research

A tissue simulating gel and a method for preparing the tissue simulating gel are disclosed. The tissue simulating gel is prepared by a process using water, gelatin, ethylene glycol, and a cross-linking agent. In order to closely approximate the characteristics of the type of tissue being simulated, other material has been added to change the electrical, sound conducting, and wave scattering properties of the tissue simulating gel. The result of the entire process is a formulation that will not melt at the elevated temperatures involved in hyperthermia medical research. Furthermore, the tissue simulating gel will not support mold or bacterial growth, is of a sufficient mechanical strength to maintain a desired shape without a supporting shell, and is non-hardening and non-drying. Substances have been injected into the tissue simulating gel prior to the setting-up thereof just as they could be injected into actual tissue, and the tissue simulating gel is translucent so as to permit visual inspection of its interior. A polyurethane spray often used for coating circuit boards can be applied to the surface of the tissue simulating gel to give a texture similar to human skin, making the tissue simulating gel easier to handle and contributing to its longevity.

Companion, John A.↗

NASA NTRSDate not supplied

Computation of Effective Mechanical Properties and Mechanical Erosion Modeling of TPS Materials

The goal of this presentation is to provide a general overview of the multi-scale modeling formulation to determine if there is additional surface recession in Thermal Protection Systems (TPS) materials as a result of mechanical erosion due to high shear conditions during atmospheric entry. This modeling process is performed at different scales by leveraging two computational frameworks developed at NASA: the Porous Microstructure Analysis (PuMA) software, and the Porous material Analysis Toolbox based on OpenFOAM (PATO). PuMA specializes in computing effective macro-scale material properties by performing material response simulations on 3D digital micro-scale representations of porous micro-structures. The modeling of TPS materials at the micro-scale is essential to understand how they behave as part of a heat shield assembly. The first part of the presentation will detail the implementation of PuMA’s cell-centered finite volume elasticity solver, which allows the computation of macro-scale effective mechanical properties of heterogeneous and anisotropic materials such as fibrous and woven TPS composites. These homogenized mechanical properties are used by PATO’s mechanical erosion model to predict the TPS material’s recession at a larger scale. This work will also provide some examples of multi-scale analysis from the fiber level up to the unit cell. The second part of the presentation will focus on the macro-scale approach to determine if erosion at the heat shield’s surface occurs due to mechanical and thermal loads experienced during atmospheric entry. To accomplish this, a solid mechanics module was integrated within PATO enabling it to model the potential mechanical erosion in three steps: first, after obtaining the effective mechanical properties with PuMA, the implemented stress analysis solver computes the stress and the displacement fields for the TPS material using the wall shear stress tensor, computed using a CFD solver, as boundary conditions; then, regions on the surface where the stress meets the failure criteria are identified; finally, the failed material is removed and the mesh is redistributed accordingly. The outcome is a model capable of predicting the total recession in the material due to surface chemistry and mechanical erosion.

Mechanical Properties↗

NASA NTRS2010

Preliminary Geological Findings on the BP-1 Simulant

A waste material from an aggregate producing quarry has been used to make an inexpensive lunar simulant called BP-1. The feedstock is the Black Point lava flow in northern Arizona. Although this is part of the San Francisco volcanic field, which is also the source of the JSC-1 series feedstock, BP-1 and JSC-1 are distinct. Chemically, the Black Point flow is an amygdaloidal nepheline-bearing basalt. The amygdules are filled with secondary minerals containing opaline silica, calcium carbonate, and ferric iron minerals. X-ray diffraction (XRD) detected approximately 3% quartz, which is in line with tests done by the Kennedy Space Center Industrial Hygiene Office. Users of this material should use appropriate protective equipment. XRD also showed the presence of significant halite and some bassanite. Both are interpreted to be evaporative residues due to recycling of wash water at the quarry. The size distribution of BP-1 may be superior to some other simulants for some applications.

Stoeser, D. B.↗

NASA NTRS2004

Safety Aboard the International Space Station

As with any task that NASA takes on, safety is of utmost importaqce. There are pages of safety codes and procedures that must be followed before any idea can be brought to life. Unfortunately, the International Space Station s (ISS) safety regulations and procedures are based on lg standards rather than on Og. To aide in making this space age home away from home a less hazardous environment, I worked on several projects revolving around the dangers of flammable items in microgravity. The first task I was assigned was to track flames. This involves turning eight millimeter video recordings, of tests run in the five second drop tower, into avi format on the computer. The footage is then compressed and altered so that the flame can be seen more clearly. Using another program called Spotlight, line profiles were used to collect data describing the luminescence of the flame at different points. These raw data are saved as text files and run trough a macro so that a Matlab program can analyze it. By fitting the data to a curve and determining the areas of brightest luminescence, the behavior of the flame can be recorded numerically. After entering the data into a database, researchers can come back later and easily get information on flames resulting from different gas and liquid mixtures in microgravity. I also worked on phase two of the FATE project, which deals with safety aboard the ISS. This phase involves igniting projected droplets and determining how they react with secondary materials. Such simulations represent, on a small scale, the spread of onboard fires due to the effervescence of burning primary materials. I set up existing hardware to operate these experiments and ran tests with it, photographing the results. I also made CAD drawings of the apparatus and the area available on the (SF)2 rig for it to fit into. The experiment will later be performed on the KC-135, and the results gathered will be used to reanalyze current safety standards for the ISS, including the distance of required separation for flammable materials. Additional information is included in the original extended abstract.

Mintz, Shauna M.↗

NASA NTRSDate not supplied

Alteration of Optical Properties in Polymer Materials under Low Earth Orbit (LEO) Space and Simulated Exposure

This paper provides an overview of the 16th Materials International Space Station Experiment (MISSE) project, conducted by a multiorganizational team of researchers. The orbital environment during the mission, including environmental sensors data and unexpected occurrences, are discussed. The research further examines the spectral changes in selected material, Kapton TF, exposed to low Earth orbit conditions during the mission. Optical images of the material taken during the mission were analyzed using a machine learning approach. This process involved the use of a Radial Basis Function network to extract reflectance spectra from RGB/IR images. The findings were then compared with lab-based experiments of identical materials subjected to simulated space weather conditions. This comprehensive study aids in making accurate predictions about the performance of materials in space, thereby improving the reliability and safety of future space missions.

Insulators↗

NASA NTRSDate not supplied

Recent Advancements in the PATO Material Response Code

Introduction: Predicting the complicated multiphysics phenomena during atmospheric entry requires high-fidelity modeling tools to refine estimates of mission risks during entry. To this end, new capabilities are being added to the Porous-material Analysis Toolbox based on OpenFOAM (PATO). PATO is an open-source software for Computational Material Response (CMR) of reactive porous materials submitted to high-temperature environments. The objective of this work is to highlight current efforts to add to and improve upon the modeling capabilities of PATO. These include efforts to loosely couple PATO with other discipline specialized codes including hypersonic Computational Fluid Dynamics (CFD), to assess the interaction effects between pyrolysis gas blowing and the boundary layer, and Computational Solid Mechanics (CSM), to address modeling of mechanical erosion. Other refinements include surface phenomena modeling capabilities to address the effects of silicone-based coatings applied to the TPS during flight preparation, and a unified multiphase solver for a mixed porous-material and plain-fluid domain. Coupling CMR with CFD (CMR/CFD): A loose coupling between PATO and the Data Parallel Line Relaxation (DPLR) CFD code has been achieved by making use of a blowing boundary condition at the heatshield surface available in DPLR. Starting with heat flux estimates with no pyrolysis gas blowing at the surface, blowing gases are computed by the CMR and passed to the CFD such that aerothermal properties of the environment can be recomputed for a new CMR computation. This leads to an iterative process which is supplemented with an estimate of the radiative heat flux using the Nonequilibrium air radiation (NEQAIR) program. The entire iterative process is illustrated in Figure 1. This coupling strategy has been utilized in computing the MSL material response. The goal is to compare the coupled CMR/CFD results with material response results obtained using traditional blowing corrections. Coupling CMS with CMR: A mechanical erosion model is currently being implemented in PATO to account for the additional mass removal induced by high shear conditions. The modeling process at each timestep consists of updating the mechanical properties as a function of temperature and computing the stress tensor and displacement fields of the material. Then, a failure criteria model determines the regions in which the stress exceeds the ultimate strength values resulting in mesh movement to account for mass removal. This model allows the material response simulation to compute the recession due to both oxidation and shear-induced erosion. The model is demonstrated by computing material response of sphere-cone arc jet samples. Surface Modeling Capabilities: NuSil, a silicone-based coating, was sprayed onto the MSL and Mars 2020 heatshields to mitigate shedding of phenolic dust. To better understand the effects of the NuSil coating on the material response, a novel model has been implemented in PATO. In this model, the equilibrium of the charred NuSil surface is modeled as pure silica, and a constant offset, inspired by the classical spallation model, is added to the the char blowing rate and wall enthalpy to reproduce HyMETS experimental results. The model has also been used to estimate the 3D material response of the MSL heatshield. Unified Solver: In addition to the iterative loose coupling approach mentioned above, a multiphase unified solver is being developed to couple the environment (plain-fluid phase) and the porous-material phase. The solver is based on the volume averaged conservation of mass, momentum, and energy for the macroscale with closure models which include microscale effects through effective physicochemical properties. The unified solver has been used to compute flow through a porous plug and solve the Beavers and Joseph problem. Since the strong coupling between phases is inherent to this solver, modeling assumptions present in other coupling methods of material response are mitigated. This strategy also makes it feasible to capture the competition between surface and volume ablation in the same computational domain, which is usually not possible with other coupling approaches.

Material Response↗

NASA NTRSDate not supplied

Recent Advancements in the PATO Material Response Code

Introduction: Predicting the complicated multiphysics phenomena during atmospheric entry requires high-fidelity modeling tools to refine estimates of mission risks during entry. To this end, new capabilities are being added to the Porous-material Analysis Toolbox based on OpenFOAM (PATO) [1,2,3]. PATO is an open-source software for Computational Material Response (CMR) of reactive porous materials submitted to high-temperature environments. The objective of this work is to highlight current efforts to add to and improve upon the modeling capabilities of PATO. These include efforts to loosely couple PATO with other discipline specialized codes including hypersonic Computational Fluid Dynamics (CFD), to assess the interaction effects between pyrolysis gas blowing and the boundary layer, and Computational Solid Mechanics (CSM), to address modeling of mechanical erosion. Other refinements include surface phenomena modeling capabilities to address the effects of silicone-based coatings applied to the TPS during flight preparation, and a unified multiphase solver for a mixed porous-material and plain-fluid domain. Coupling CMR with CFD (CMR/CFD): A loose coupling between PATO and the Data Parallel Line Relaxation (DPLR) [4] CFD code has been achieved by making use of a blowing boundary condition at the heatshield surface available in DPLR. Starting with heat flux estimates with no pyrolysis gas blowing at the surface, blowing gases are computed by the CMR and passed to the CFD such that aerothermal properties of the environment can be recomputed for a new CMR computation. This leads to an iterative process which is supplemented with an estimate of the radiative heat flux using the Nonequilibrium air radiation (NEQAIR) [5] program. The entire iterative process is illustrated in Figure 1. This coupling strategy has been utilized in computing the MSL material response. The goal is to compare the coupled CMR/CFD results with material response results obtained using traditional blowing corrections. Coupling CMS with CMR: A mechanical erosion model is currently being implemented in PATO to account for the additional mass removal induced by high shear conditions. The modeling process at each timestep consists of updating the mechanical properties as a function of temperature and computing the stress tensor and displacement fields of the material. Then, a failure criteria model determines the regions in which the stress exceeds the ultimate strength values resulting in mesh movement to account for mass removal. This model allows the material response simulation to compute the recession due to both oxidation and shear-induced erosion. The model is demonstrated by computing material response of sphere-cone arc jet samples. Surface Modeling Capabilities: NuSil, a silicone-based coating, was sprayed onto the MSL and Mars 2020 heatshields to mitigate shedding of phenolic dust. To better understand the effects of the NuSil coating on the material response, a novel model has been implemented in PATO. In this model, the equilibrium of the charred NuSil surface is modeled as pure silica, and a constant offset, inspired by the classical spallation model, is added to the the char blowing rate and wall enthalpy to reproduce HyMETS experimental results. The model has also been used to estimate the 3D material response of the MSL heatshield [6]. Unified Solver: In addition to the iterative loose coupling approach mentioned above, a multiphase unified solver is being developed to couple the environment (plain-fluid phase) and the porous-material phase. The solver is based on the volume averaged conservation of mass, momentum, and energy for the macroscale with closure models which include microscale effects through effective physicochemical properties. The unified solver has been used to compute flow through a porous plug and solve the Beavers and Joseph problem [7]. Since the strong coupling between phases is inherent to this solver, modeling assumptions present in other coupling methods of material response are mitigated. This strategy also makes it feasible to capture the competition between surface and volume ablation in the same computational domain, which is usually not possible with other coupling approaches.

Thermal Protection Systems↗

NASA NTRS2010

Three-Body Abrasion Testing Using Lunar Dust Simulants to Evaluate Surface System Materials

Numerous unexpected operational issues relating to the abrasive nature of lunar dust, such as scratched visors and spacesuit pressure seal leaks, were encountered during the Apollo missions. To avoid reoccurrence of these unexpected detrimental equipment problems on future missions to the Moon, a series of two- and three-body abrasion tests were developed and conducted in order to begin rigorously characterizing the effect of lunar dust abrasiveness on candidate surface system materials. Two-body scratch tests were initially performed to examine fundamental interactions of a single particle on a flat surface. These simple and robust tests were used to establish standardized measurement techniques for quantifying controlled volumetric wear. Subsequent efforts described in the paper involved three-body abrasion testing designed to be more representative of actual lunar interactions. For these tests, a new tribotester was developed to expose samples to a variety of industrial abrasives and lunar simulants. The work discussed in this paper describes the three-body hardware setup consisting of a rotating rubber wheel that applies a load on a specimen as a loose abrasive is fed into the system. The test methodology is based on ASTM International (ASTM) B611, except it does not mix water with the abrasive. All tests were run under identical conditions. Abraded material specimens included poly(methyl methacrylate) (PMMA), hardened 1045 steel, 6061-T6 aluminum (Al) and 1018 steel. Abrasives included lunar mare simulant JSC- 1A-F (nominal size distribution), sieved JSC-1A-F (<25 m particle diameter), lunar highland simulant NU-LHT-2M, alumina (average diameter of 50 m used per ASTM G76), and silica (50/70 mesh used per ASTM G65). The measured mass loss from each specimen was converted using standard densities to determine total wear volume in cm3. Abrasion was dominated by the alumina and the simulants were only similar to the silica (i.e., sand) on the softer materials of aluminum and PMMA. The nominal JSC- 1A-F consistently showed more abrasion wear than the sieved version of the simulant. The lunar dust displayed abrasivity to all of the test materials, which are likely to be used in lunar landing equipment. Based on this test experience and pilot results obtained, recommendations are made for systematic abrasion testing of candidate materials intended for use in lunar exploration systems and in other environments with similar dust challenges.

Kobrick, Ryan L.↗

NASA NTRSDate not supplied

Material Properties and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

PATO↗