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NASA NTRS1998

Integrated Thermal Insulation System for Spacecraft

An integrated thermal protection system (TPS) for a spacecraft includes a grid that is bonded to skin of the spacecraft, e.g., to support the structural loads of the spacecraft. A plurality of thermally insulative, relatively large panels are positioned on the grid to cover the skin of the spacecraft to which the grid has been bonded. Each panel includes a rounded front edge and a front flange depending downwardly from the front edge. Also, each panel includes a rear edge formed with a rounded socket for receiving the rounded front edge of another panel therein, and a respective rear flange depends downwardly from each rear edge. Pins are formed on the front flanges, and pin receptacles are formed on the rear flanges, such that the pins of a panel mechanically interlock with the receptacles of the immediately forward panel. To reduce the transfer to the skin of heat which happens to leak through the panels to the grid, the grid includes stringers that are chair-shaped in cross-section.

Kolodziej, Paul↗

NASA NTRS2003

Internal Flow Thermal/Fluid Modeling of STS-107 Port Wing in Support of the Columbia Accident Investigation Board

As part of the aero-thermodynamics team supporting the Columbia Accident Investigation Board (CAB), the Marshall Space Flight Center was asked to perform engineering analyses of internal flows in the port wing. The aero-thermodynamics team was split into internal flow and external flow teams with the support being divided between shorter timeframe engineering methods and more complex computational fluid dynamics. In order to gain a rough order of magnitude type of knowledge of the internal flow in the port wing for various breach locations and sizes (as theorized by the CAB to have caused the Columbia re-entry failure), a bulk venting model was required to input boundary flow rates and pressures to the computational fluid dynamics (CFD) analyses. This paper summarizes the modeling that was done by MSFC in Thermal Desktop. A venting model of the entire Orbiter was constructed in FloCAD based on Rockwell International s flight substantiation analyses and the STS-107 reentry trajectory. Chemical equilibrium air thermodynamic properties were generated for SINDA/FLUINT s fluid property routines from a code provided by Langley Research Center. In parallel, a simplified thermal mathematical model of the port wing, including the Thermal Protection System (TPS), was based on more detailed Shuttle re-entry modeling previously done by the Dryden Flight Research Center. Once the venting model was coupled with the thermal model of the wing structure with chemical equilibrium air properties, various breach scenarios were assessed in support of the aero-thermodynamics team. The construction of the coupled model and results are presented herein.

Sharp, John R.↗

NASA NTRS2019

Heatshield Erosion Due to Dust Particle Impacts on the Schiaparelli Capsule During Martian Entry

One of the unique features of spacecraft entering the atmosphere of Mars is the possibility of a major dust storm occurring during the entry. Design of the thermal protection system (TPS) for Mars missions have to account for the possibility of dust erosion when estimating the thickness of the TPS. Because weight is always a critical factor in designing entry vehicles, accurate assessment of dust erosion is necessary to avoid over-design of the TPS.This study will present computational results of heatshield erosion due to dust particle impacts on the ExoMars Schiaparelli capsule if it had encountered a dust storm during its October 2016 entry. A one-way coupling approach is used where particle trajectories are computed based on an underlying CFD flow solution. Based on a distribution of particle sizes ranging from 1 to 18 microns in diameter, the Icarus material response solver predicted approximately 1 mm of TPS heatshield erosion due to particle impacts, which was 40% of the value due to material charring.

thermal protection system↗

NASA NTRS2015

Conformal Ablative Thermal Protection System for Small and Large Scale Missions: Approaching TRL 6 for Planetary and Human Exploration Missions and TRL 9 for Small Probe Missions

In 2011, NASAs Aeronautics Research Mission Directorate (ARMD) funded an effort to develop an ablative thermal protection system (TPS) material that would have improved properties when compared to Phenolic Impregnated Carbon Ablator (PICA) and AVCOAT. Their goal was a conformal material, processed with a flexible reinforcement that would result in similar or better thermal characteristics and higher strain-to-failure characteristics that would allow for easier integration on flight aeroshells than then-current rigid ablative TPS materials. In 2012, NASAs Space Technology Mission Directorate (STMD) began funding the maturation of the best formulation of the game changing conformal ablator, C-PICA. Progress has been reported at IPPW over the past three years, describing C-PICA with a density and recession rates similar to PICA, but with a higher strain-to-failure which allows for direct bonding and no gap fillers, and even more important, with thermal characteristics resulting in half the temperature rise of PICA. Overall, C-PICA should be able to replace PICA with a thinner, lighter weight, less complicated design. These characteristics should be particularly attractive for use as backshell TPS on high energy planetary entry vehicles. At the end of this year, the material should be ready for missions to consider including in their design, in fact, NASAs Science Mission Directorate (SMD) is considering incentivizing the use of C-PICA in the next Discovery Proposal call. This year both scale up of the material to large (1-m) sized pieces and the design and build of small probe heatshields for flight tests will be completed. NASA, with an industry partner, will build a 1-m long manufacturing demonstration unit (MDU) with a shape based on a mid LD lifting body. In addition, in an effort to fly as you test and test as you fly, NASA, with a second industry partner, will build a small probe to test in the Interactive Heating Facility (IHF) arc jet and, using nearly the same design, build the aeroshell and TPS, with instrumentation, for a small probe flight test article, due to fly in 2017. At the end of the year, the C-PICA will be at TRL 5+, and with the flight data in 2017, it will be at TRL 9 for missions needs with C-PICA at a small scale (12 diameter). The scale-up and small probe efforts will be de-scribed in this presentation.

Conformal Ablative↗

NASA NTRSDate not supplied

Segmentation of Lightweight Ablator Micro-Tomography Using Deep Learning

Ablative thermal protection systems (TPS) are essential for high speed entry of planetary atmospheres, such as those of Earth and Mars. Upon entry the kinetic energy of the spacecraft is converted into thermal energy, leading to high heat fluxes at the wall of the craft. Because of this extreme heating, a robust ablative TPS material must be selected. A common material selection today is phenolic-impregnated carbon ablator (PICA), which is a low-density carbon material known for producing dust that is not suitable to a cleanroom environment. To mitigate dust created by a PICA heatshield, a silicone-based spray called NuSil is applied to the surface of the TPS, creating PICA-NuSil (PICA-N). PICA-N has been observed to have a different material response from regular PICA during high enthalpy flow testing, producing surface temperatures up to 200K less than those seen for PICA [1]. To better understand this phenomenon, it is critical that robust methods of PICA-N material characterization are developed. The purpose of this project is to investigate Object Research Systems’ (ORS) Dragonfly deep learning tools as a means of accurately segmenting and characterizing PICA-N. Systematic testing of this software has shown that Dragonfly deep learning tools have strong potential for accurate segmentation/ characterization of PICA-N and other TPS materials.

Micro-tomography↗

NASA NTRSDate not supplied

Developments on Reusable TPS Materials Based Upon Shuttle Tile

The insulating tiles used on the Space Shuttler Orbiter, principally AETB (Alumina Enhanced Thermal Barrier), have been seen by new vehicle developers in the aerospace industry as a fast-track approach for fielding a reusable thermal protection system (TPS) given the extensive use by both the Orbiter program and the current Orion vehicle. NASA has, and is, supporting the industry through technology transfer and commercial crew and payloads programs. However, the reusable TPS community is rapidly encountering challenges rooted in Orbiter’s and Orion’s dependence on legacy material and processes. With the aim of alleviating these issues, improving availability of reusable TPS, and strengthening the nation’s space economy, ongoing efforts at NASA Ames have focused on understanding process-property relationships in AETB as well as novel materials and technologies for reusable TPS. The first portion of this talk will address the effects of raw materials and processing conditions on the properties of AETB-8, including the raw materials used, mixing and casting parameters, and thermal history. Understanding these relationships, and how they extend to aerothermal performance, is instrumental in alleviating supply chain constraints and improving manufacturability. The implications of these finding on development of novel TPS materials and systems will be discussed. AETB will likely continue to fill a niche of relatively high performance with associated costs. There exists, therefore, a gap in developed reusable TPS for a lower cost, moderate performing material system. The later portion of this talk will touch on current development efforts at Ames focusing on reduced cost and ease of integration, which are being pursued in addition to AETB and higher performing systems. In addition to summarizing these efforts, an outlook for these projects and collaborations will be given.

Peter Edward Marshall↗

NASA NTRS2014

Nonlinear Aeroelastic Analysis of the HIAD TPS Coupon in the NASA 8' High Temperature Tunnel: Theory and Experiment

The purpose of this work is to develop a set of theoretical and experimental techniques to characterize the aeroelasticity of the thermal protection system (TPS) on the NASA Hypersonic Inflatable Aerodynamic Decelerator (HIAD). A square TPS coupon experiences trailing edge oscillatory behavior during experimental testing in the 8' High Temperature Tunnel (HTT), which may indicate the presence of aeroelastic flutter. Several theoretical aeroelastic models have been developed, each corresponding to a different experimental test configuration. Von Karman large deflection theory is used for the plate-like components of the TPS, along with piston theory for the aerodynamics. The constraints between the individual TPS layers and the presence of a unidirectional foundation at the back of the coupon are included by developing the necessary energy expressions and using the Rayleigh Ritz method to derive the nonlinear equations of motion. Free vibrations and limit cycle oscillations are computed and the frequencies and amplitudes are compared with accelerometer and photogrammetry data from the experiments.

Benjamin D. Goldman↗

NASA NTRS1998

Thermal Management Design for the X-33 Lifting Body

The X-33 Advantage Technology Demonstrator offers a rare and exciting opportunity in Thermal Protection System development. The experimental program incorporates the latest design innovation in re-useable, low life cycle cost, and highly dependable Thermal Protection materials and constructions into both ground based and flight test vehicle validations. The unique attributes of the X-33 demonstrator for design application validation for the full scale Reusable Launch Vehicle, (RLV), are represented by both the configuration of the stand-off aeroshell, and the extreme exposures of sub-orbital hypersonic re-entry simulation. There are several challenges of producing a sub-orbital prototype demonstrator of Single Stage to Orbit/Reusable Launch Vehicle (SSTO/RLV) operations. An aggressive schedule with budgetary constraints precludes the opportunity for an extensive verification and qualification program of vehicle flight hardware. However, taking advantage of off the shelf components with proven technologies reduces some of the requirements for additional testing. The effects of scale on thermal heating rates must also be taken into account during trajectory design and analysis. Described in this document are the unique Thermal Protection System (TPS) design opportunities that are available with the lifting body configuration of the X-33. The two principal objectives for the TPS are to shield the primary airframe structure from excessive thermal loads and to provide an aerodynamic mold line surface. With the relatively benign aeroheating capability of the lifting body, an integrated stand-off aeroshell design with minimal weight and reduced procurement and operational costs is allowed. This paper summarizes the design objectives of the X-33 TPS, the flight test requirements driven configuration, and design benefits. Comparisons are made of the X-33 flight profiles and Space Shuttle Orbiter, and lifting body Reusable Launch Vehicle aerothermal environments. The X-33 TPS is based on a design to cost configuration concept. Only RLV critical technologies are verified to conform to cost and schedule restrictions. The one-off prototype vehicle configuration has evolved to minimize the tooling costs by reducing the number of unique components. Low cost approaches such as a composite/blanket leeward aeroshell and the use of Shuttle technology are implemented where applicable. The success of the X-33 will overcome the ballistic re-entry TPS mindset. The X-33 TPS is tailored to an aircraft type mission while maintaining sufficient operational margins. The flight test program for the X-33 will demonstrate that TPS for the RLV is not simply a surface insulation but rather an integrated aeroshell system.

Bouslog, S.↗

NASA NTRS2018

Estimation of Heatshield Mass Loss for Mars 2020 Entry Vehicle

The Mars2020 entry vehicle is currently being developed by NASA to safely land its next rover on the Martian surface in 2021. During entry, the vehicle will be protected from aerothermal environments using a PICA (Phenolic Impregnated Carbon Ablator)-tiled heatshield. PICA loses mass through surface recession and in-depth pyrolysis as it is heated. Pre-flight knowledge of heatshield mass loss is required for vehicle balancing during critical mission events. This study attempts to predict the total mass loss experienced by the Mars2020's heatshield during its entry. A grid was created over the half of the heatshield which generated 108 points across a total of 9 spokes. Aero-thermal environments were provided from CFD (Computational Fluid Dynamics) calculations that considered a baselined trajectory. The TPS (Thermal Protection System) stack was a build-up of composite, aluminum, composite, an HT-424 bond, followed by PICA. The FIAT (Fully Implicit Ablation, Thermal-response) 1-D analysis utilized this TPS stack and the CFD environments and was run at each grid point giving mass flux information from the point of atmospheric entry until parachute deployment. The mass flux due to recession and pyrolysis gas was summed and integrated first through time and then across the half heatshield using a polar integration tool. The mass loss results were mirrored to the other half of the heatshield to calculate total mass loss throughout the entry phase of flight. This total mass loss value and its distribution was used by entry vehicle designers to account for CG (Center of Gravity) offset during parachute descent when the heatshield is no longer losing significant mass.

PICA↗

NASA NTRS2024

Enhancing the Protection of Shielded Thermal Protection Systems in Sample Return Spacecraft Against MMOD Impact

Sample return missions seek to collect samples from planets, moons, asteroids, and other planetary bodies and return them to earth for in-depth analysis. Backward planetary protection requirements are often in place for such missions to prevent the introduction of any extra-terrestrial material into the Earth’s biosphere, which could occur if a meteoroid or space debris particle were to damage a critical part of the returning spacecraft. The ability of a shielding system used to mitigate this damage risk is typically characterized by a ballistic limit equation (BLE), which predicts whether or not a protected system or structural element will sustain a critical failure due to a high-speed impact. In this paper, we develop a particle-impact-based BLE for the thermal protection system (TPS) of a sample return spacecraft that is protected by a multi-shock shield. The predictions of the BLE we develop for TPS failure are shown to be consistent with the predictions of hydrocode simulations.

Sample Return Spacecraft↗

NASA NTRS2016

Earth Entry Requirements for Mars, Europa and Enceladus Sample Return Missions: A Thermal Protection System Perspective

This oral presentation will be given at the 13th International Planetary Probe Workshop on June 14th, 2016 and will cover the drivers for reliability and the challenges faced in selecting and designing the thermal protection system (TPS). In addition, an assessment is made on new emerging TPS related technologies that could help with designs to meet the planetary protection requirements to prevent backward (Earth) contamination by biohazardous samples.

Earth Entry↗

NASA NTRS1972

Thermal support for space shuttle

The results are reported of research to provide thermal support in the design of the thermal protection system (TPS) of the space shuttles. Tasks discussed include: generation of temperature boundaries for space shuttle orbiter and booster during atmospheric reentry, leading edge and nose cap materials, TPS panel test facility support, thermal test facility support, and hot gas test facility support. A summary of thermal models generated for the space shuttle support is included.

Dean, W. G.↗

NASA NTRS2011

PICA Variants with Improved Mechanical Properties

Phenolic Impregnated Carbon Ablator (PICA) is a member of the family of Lightweight Ceramic Ablators (LCAs) and was developed at NASA Ames Research Center as a thermal protection system (TPS) material for the Stardust mission probe that entered the Earth s atmosphere faster than any other probe or vehicle to date. PICA, carbon fiberform base and phenolic polymer, shows excellent thermal insulative properties at heating rates from about 250 W/sq cm to 1000 W/sq cm. The density of standard PICA - 0.26 g/cu cm to 0.28 g/cu cm - can be changed by changing the concentration of the phenolic resin. By adding polymers to the phenolic resin before curing it is possible to significantly improve the mechanical properties of PICA without significantly increasing the density.

Thornton, Jeremy↗

NASA NTRSDate not supplied

Material Response Modeling of Ablative Thermal Protection Systems using PATO

Developing thermal protection systems (TPS) for future space vehicles involves an extensive design and test cycle. A key component of the cycle is determining margins for a safe design that rely on confidence in the performance of the TPS. Predicting the complicated multiphysics phenomena that occur during atmospheric entry requires high-fidelity modeling tools. To this end, the Porous-material Analysis Toolbox based on OpenFOAM (PATO) has been developed. PATO is an open-source software for computing material response of reactive porous materials submitted to high-temperature environments. Recent applications of PATO include computation of the full heatshield 3D material response from the Mars Science Laboratory atmospheric entry and ablation during arc jet testing. Current efforts are underway to loosely couple PATO with other discipline specialized codes including hypersonic computational fluid dynamics (CFD) to assess the effects of pyrolysis-gas blowing into the boundary layer and computational solid mechanics to address modeling of mechanical erosion. Surface phenomena modeling capabilities to address the effects of silicone-based coatings applied to the TPS during flight preparation are also being added.

Thermal Protection Systems↗

NASA NTRSDate not supplied

Material Response Modeling of Ablative Thermal Protection Systems using PATO

Thermal Protection Systems↗

NASA NTRS1990

A preliminary TPS design for MRSR - Aerobraking at Mars and at earth

An investigation was made to determine the feasibility of using an aerobrake system for an unmanned mission to Mars and for a return vehicle to earth. A preliminary thermal protection system (TPS) is examined for two small nose radius, straight biconic vehicles aerocapturing at Mars. The TPS for these vehicles, entering at 6 km/s and 8 km/s, are shown to have an advantage over a propulsive burn velocity reduction for orbit insertion. The TPS for each vehicle consisted of an ablator in the region of high heating, and reusable insulation over the rest of the structure. It was determined that a reusable TPS could be used over 98 percent of the aeroshell structure. Also presented is the preliminary TPS design for an Apollo-shaped vehicle aerocapturing at earth. As with the biconics, this vehicle had an ablator in the region of high heating, and reusable insulation on the aft conic section. In contrast to the vehicles aerocapturing at Mars, the ablator is used on 63 percent of the vehicle's aeroshell structure.

Williams, S. D.↗

NASA NTRS1991

TPS design for aerobraking at Earth and Mars

An investigation was made to determine the feasibility of using an aerobrake system for manned and unmanned missions to Mars, and to Earth from Mars and lunar orbits. A preliminary thermal protection system (TPS) was examined for five unmanned small nose radius, straight bi-conic vehicles and a scaled up Aeroassist Flight Experiment (AFE) vehicle aerocapturing at Mars. Analyses were also conducted for the scaled up AFE and an unmanned Sample Return Cannister (SRC) returning from Mars and aerocapturing into Earth orbit. Also analyzed were three different classes of lunar transfer vehicles (LTV's): an expendable scaled up modified Apollo Command Module (CM), a raked cone (modified AFT), and three large nose radius domed cylinders. The LTV's would be used to transport personnel and supplies between Earth and the moon in order to establish a manned base on the lunar surface. The TPS for all vehicles analyzed is shown to have an advantage over an all-propulsive velocity reduction for orbit insertion. Results indicate that TPS weight penalties of less than 28 percent can be achieved using current material technology, and slightly less than the most favorable LTV using advanced material technology.

Williams, S. D.↗

NASA NTRS2023

Experimental Investigation of Block-TPS Fence/Gap Roughness Effects on Transition Onset and Turbulent Heating at Mach 6

An experimental investigation of boundary-layer transition and convective surface heating on wind tunnel models that simulated aeroshells comprised of multiple blocks of thermal protection system (TPS) material has been performed. Two representative entry vehicle geometries, a sphere-cone aeroshell and a sphere-cone aeroshell, were considered. Multiple cast ceramic models of each geometry were fabricated with varying fence heights or gap depths to represent gap fillers that either protrude above, or are recessed below, the TPS blocks due to differential ablation during reentry. Wind tunnel testing was performed at Mach 6 over a range of Reynolds numbers sufficient to produce laminar, transitional, and turbulent flow. Convective surface heating and boundary-layer transition onset data were obtained using global phosphor thermography. The experimental heating data are presented herein, as are comparisons to laminar and turbulent smooth-wall heat transfer distributions from computational flow field simulations.

Aerothermodynamics↗