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At least 343 records · Page 19

An Update to a Conformal Ablative Thermal Protection System for Planetary and Human Exploration Missions

As described at IPPW-10, in FY12, the CA-TPS element focused on establishing materials requirements based on MSL-type and COTS Low Earth orbit (LEO) conditions (q 250 Wcm2) to develop and deliver a conformal ablative TPS. This involved down selecting, manufacturing and testing two of the best candidate materials, demonstrating uniform infiltration of resins into baseline 2-cm thick carbon felt, selecting a primary conformal material formulation based on novel arc jet and basic material properties testing, developing and demonstrating instrumentation for felt-based materials and, based on the data, developing a low fidelity material response model so that the conformal ablator TPS thickness for missions could be established. In addition, the project began to develop Industry Partnerships. Since the nominal thickness of baseline carbon felts was only 2-cm, a partnership with a rayon felt developer was made in order to upgrade equipment, establish the processes required and attempt to manufacture 10-cm thick white goods. A partnership with a processing house was made to develop the methodology to carbonize large pieces of the white goods into 7.5-cm thick carbon felt. In FY13, more advanced testing and modeling of the down selected conformal material was performed. Material thermal properties tests and structural properties tests were performed. The first 3 and 4-point bend tests were performed on the conformal ablator as well as PICA for comparison and the conformal ablator had outstanding behavior compared to PICA. Arc jet testing was performed with instrumented samples of both the conformal ablator and standard PICA at heating rates ranging from 40 to 400 Wcm2 and shear as high as 600 Pa. The results from these tests showed a remarkable improvement in the thermal penetration through the conformal ablator when compared to PICAs response. The data from these tests were used to develop a mid-fidelity thermal response model. Additional arc jet testing in the same conditions on various seam designs were very successful in showing that the material could be joined with a minimum of adhesive and required no complicated gap and gap filler design for installation. In addition, the partnership with industry to manufacture thicker rayon felt was very successful. The vendor made a 2-m wide by 30-m long sample of 10-cm thick rayon felt. When carbonized, the resulting thickness was over 7.5-cm thick, nearly 4 times the thickest off-the-shelf carbon felt. In FY14, the project has initiated a partnership with another vendor to begin the scale-up manufacturing effort. This year, the vendor will duplicate the process and manufacture at the current scale for comparison with NASA-processed materials. Properties testing and arc jet testing will be performed on the vendor-processed materials. Planning for manufacturing large, 1-m x 1-m, panels will begin as well. In FY15, the vendor will then manufacture large panels and the project will build a 2-m x 2-m Manufacturing Demonstration Unit (MDU).

Ablative materials↗

Modeling In-Space Aborts for NASA Human Exploration Missions

NASA is developing capabilities for crewed missions beyond Low Earth Orbit (LEO) for the first time in nearly 50 years. Given the greater distances from Earth that these missions will entail, it is prudent to develop in-space abort capabilities in order to save the crew in the event of critical life-threatening failures that may occur. NASA has developed a Cross Program PRA (XPRA) of the integrated vehicle, from pre-launch through landing and rescue of the crew. An ascent abort model has already been developed as part of this XPRA model to assess the risk associated with failures during prelaunch and ascent. The scope of the analysis discussed here is focused on aborts associated with the in-space portion of the mission up to and including the Trans-Lunar Injection (TLI) burn, which places the Orion spacecraft on a trajectory to the Moon.

Bigler, Mark A.↗

Magnetohydrodynamics (MHD) Aerocapture System for Enabling Faster-Larger Planetary Science & Human Exploration Missions

Since our completing the NIAC Phase I NIAC on this Advanced Aerocapture System, NASA Langley Research Center has funded or supported a number of studies and code enhancements through its Center Innovation Fund (CIF) and NASA’s NSTGRO and Internship Programs to mature the analysis capabilities and quantify the merits of the MHD Aerocapture System technology. These efforts have resulted in a plug and play analysis capability for assessing MHD aerocapture system performance for arrival at many planetary bodies of interest. Our efforts have especially focused on the potential mass savings for improving the capacity for science observations at Neptune and Triton. A re-cent Forbes article published “‘Orbital mechanics is probably going to decide for us whether we go to Uranus or Neptune because we need to flyby Jupiter,’ said Kunio Sayanagi at Hampton University, Virginia, who also worked on the Neptune Odyssey proposal…. Exactly when a mission can be sent to Uranus, or Neptune, depends on the relative position of Jupiter, which can help give a spacecraft a gravitational slingshot. That drastically shortens the cruise phase.” [1] Since shortening the cruise phase is important for these science missions, any mass savings enabled by the MHD Aerocapture System could be reallocated to increasing Thermal Protection System mass to allow faster arrival speeds and/or for onboarding additional payloads such as science instruments, batteries, or propellant for conducting more science for longer durations in the desired orbits. The analysis steps and codes for conducting trades and sizing vehicles for aerocapture are as follows: Step 1 is to conduct aeroheating analysis using LAURA of the selected entry vehicle shape to identify locations on the forebody where ionization and flow velocity are sufficient for producing Lo-rentz forces. LAURA is a multiblock structured grid finite-volume CFD solver developed at the NASA Langley Research Center. [2] LAURA has been used for aerothermal analysis support of the entry, de-scent and landing (EDL) phase of interplanetary missions over the last three decades [3-7]. Step 2 is to port the LAURA results into CFDWARP to calcu-late electrical and thermal conductivities of ionized flow for sizing MHD patch system and calculating Lorentz forces needed for controls analysis. CFDWARP is a CFD code that uses advanced nu-merical methods that enable the simulation of the full coupling between the aerodynamics, the magne-tohydrodynamics, and the non-neutral plasma sheaths. CFDWARP has the unique capability to simulate efficiently the non-neutral sheaths (near the electrodes) in coupled form with the quasi-neutral bulk MHD flow [8-11]. Step 3 is to link re-sults from LAURA and CFDWARP into POST2 for calculating entry trajectories and comparing MHD control results with other aerodynamic control strategies. The Program to Optimize Simulated Tra-jectories II (POST2) is a generalized point mass, discrete parameter targeting and optimization pro-gram. POST2 provides the capability to target and optimize point mass trajectories for multiple pow-ered or un-powered vehicles near an arbitrary rotat-ing, oblate planet [12]. Step 4: TPS sizing was per-formed using the Fully Implicit Ablation and Ther-mal-response code (FIAT) tool which computes the transient one-dimensional thermal response and surface thermochemistry of a multilayer stackup of thermal protection, bonding, and structural materi-als subject to aeroheating on one surface [13]. The sizing and margining methodology used was based on the approach documented by Mahzari and Milos [14] for the dual-layered heatshield for extreme entry environment technology (DL-HEEET) TPS concept. TPS analysis utilizes trajectory information from POST2. Using this step-wise plug and play MHD Aerocapture performance assessment process, our analysis targets a Neptune aerocapture trajectory that will place the spacecraft in an observation orbit for Triton. [15]. Magnetohydrodynamic (MHD) control of a 4.5-meter diameter MSL-style capsule resulted in TPS mass savings of nearly 2000 kg when using an MHD system mass of under 200 kg. The flight path for a vehicle using the MHD control strategy has a much lower heat rate and heat load compared to the conventional aerodynamic aerocapture strategies known as bank angle con-trolled (BAC) and direct force controlled (DFC). Both BAC and DFC have heat rates significantly greater than 1500 W/cm2 typically used as an upper limit for PICA. Thus, DL-HEEET TPS concept was required for the BAC and DFC control strategies. However, considering the more benign environ-ments for the MHD case, additional TPS concepts with improved mass efficiency were also assessed. PICA was considered for the MHD controlled strat-egy since the maximum heat rate was well within the limits (<1500 W/cm2) of PICA. TPS sizing re-sulted in a significant mass reduction. The PICA layer for this sizing case was about 7.8 cm. As a point of reference, the Mars 2020 mission, which used this same PICA concept, had a PICA thickness of 3.18 cm [16]. The trajectories used for the TPS sizing originat-ed from the POST2 simulations. The current, I, to an electromagnet configuration can be manipulated to allow for active control of the vehicle. Manipula-tion of the current, I, changes the magnetic field, B, which affects the Lorentz force and therefore the MHD drag force on the vehicle. Our analysis in-cluded both open-loop and close-loop control. Closed-loop control will enable improved overall performance when taking into account mission level uncertainties, such as interplanetary delivery errors and atmospheric modeling uncertainties. The open-loop and closed-loop MHD control cases do not dip as deep into the atmosphere as the aerodynamic cases. Three types of aerodynamic-only approach-es are investigated: bank angle modulation (BAM), director force control (DFC), and Drag Modulated. BAM and DFC make use of vehicle aerodynamic angles to steer the vehicle. Thus, changing the aer-odynamic forces acting on the vehicle for control, aerodynamic drag modulated case requires a vary-ing drag area to modulate the drag force. The MHD drag modulated case modulates MHD generated drag force that adds to the aerodynamic drag. This higher atmospheric activation of drag forces by the MHD patch results in significantly less heat flux on the vehicle. The MHD technology will enable shorter cruise times and deceleration of larger payloads for increasing the capacity for science at the Ice Giants or for returning astronauts to Earth from cislunar space or from Mars. The purpose of this presentation is to provide more details about this work and to highlight plans for further research and development including a flight demonstration.

R. W. Moses↗

Vehicle Shield Optimization and Risk Assessment of Future NEO Missions

Future human space missions target far destinations such as Near Earth Objects (NEO) or Mars that require extended stay in hostile radiation environments in deep space. The continuous assessment of exploration vehicles is needed to iteratively optimize the designs for shielding protection and calculating the risks associated with such long missions. We use a predictive software capability that calculates the risks to humans inside a spacecraft. The software uses the CAD software Pro/Engineer and Fishbowl tool kit to quantify the radiation shielding properties of the spacecraft geometry by calculating the areal density seen at a certain point, dose point, inside the spacecraft. The shielding results are used by NASA-developed software, BRYNTRN, to quantify the organ doses received in a human body located in the vehicle in a possible solar particle events (SPE) during such prolonged space missions. The organ doses are used to quantify the risks posed on the astronauts' health and life using NASA Space Cancer Model software. An illustration of the shielding optimization and risk calculation on an exploration vehicle design suitable for a NEO mission is provided in this study. The vehicle capsule is made of aluminum shell, airlock with hydrogen-rich carbon composite material end caps. The capsule contains sets of racks that surround a working and living area. A water shelter is provided in the middle of the vehicle to enhance the shielding in case of SPE. The mass distribution is optimized to minimize radiation hotspots and an assessment of the risks associated with a NEO mission is calculated.

Nounu, Hatem, N.↗

Mars ISRU for Production of Mission Critical Consumables - Options, Recent Studies, and Current State of the Art

In 1978, a ground breaking paper titled, "Feasibility of Rocket Propellant Production on Mars" by Ash, Dowler, and Varsi discussed how ascent propellants could be manufactured on the Mars surface from carbon dioxide collected from the atmosphere to reduce launch mass. Since then, the concept of making mission critical consumables such as propellants, fuel cell reactants, and life support consumables from local resources, commonly known as In-Situ Resource Utilization (ISRU), for robotic and human missions to Mars has been studied many times. In the late 1990's, NASA initiated a series of Mars Human Design Reference Missions (DRMs), the first of which was released in 1997. These studies primarily focused on evaluating the impact of making propellants on Mars for crew ascent to Mars orbit, but creating large caches of life support consumables (water & oxygen) as a backup for regenerative life support systems for long-duration surface stays (>500 days) was also considered in Mars DRM 3.0. Until science data from the Mars Odyssey orbiter and subsequent robotic missions revealed that water may be widely accessable across the surface of Mars, prior Mars ISRU studies were limited to processing Mars atmospheric resources (carbon dioxide, nitrogen, argon, oxygen, and water vapor). In December 2007, NASA completed the Mars Human Design Reference Architecture (DRA) 5.0 study which considered water on Mars as a potential resource for the first time in a human mission architecture. While knowledge of both water resources on Mars and the hardware required to excavate and extract the water were very preliminary, the study concluded that a significant reduction in mass and significant enhancements to the mission architecture were possible if Mars water resources were utilized. Two subsequent Mars ISRU studies aimed at reexamining ISRU technologies, processing options, and advancements in the state-of-the-art since 2007 and to better understand the volume and packaging associated with Mars ISRU systems further substantiated the preliminary results from the Mars DRA 5.0 study. This paper will provide an overview of Mars ISRU consumable production options, the analyses, results, and conclusions from the Mars DRA 5.0 (2007), Mars Collaborative (2013), and Mars ISRU Payload for the Supersonic Retro Propulsion (2014) mission studies, and the current state-of-the-art of Mars ISRU technologies and systems. The paper will also briefly discuss the mission architectural implications associated with Mars resource and ISRU processing options.

Sanders, G. B.↗

Potential Advantages of Conducting Short Duration Visits to the Martian Surface

Recent NASA concepts for human missions to Mars, including the Evolvable Mars Campaign and Design Reference Architecture 5.0, have focused on the conduct of missions with long duration stays on the Martian surface. The decision to focus on long duration missions (typically to a single site) is driven by a desire to increase the perceived sustainability of the human Mars campaign, predicated on the assumption that sustainability is best achieved by maximizing the level of activity on the surface, providing for continuous growth in operations, and promoting pioneering of Mars. However, executing a series of long duration missions to a single site is not the only option for human exploration of Mars that has been proposed. Other architectures have been evaluated that focus on missions with short duration surface stays, with each mission visiting a separate site on the surface. This type of architecture is less efficient in that elements are not typically reused from one mission to the next but requires a far less complex surface architecture. There are potentially valid arguments to be made that a short duration, multiple site approach could result in different types of advantages when compared to the long duration, single site approach to Mars exploration, particularly for initial human missions to Mars. These arguments revolve around four areas: Achieved Value, Risk Mitigation, Developmental Affordability, and Operational Affordability & Flexibility. The question of Achieved Value relates to the prioritization of goals for Martian exploration. As discussed, goals related to pioneering and expanding human presence are often referenced as justifications for the long duration approach. However, there are other competing goals, including science and exploration. While there is not a clear consensus among planetary scientists, many have argued that the value of being able to visit multiple sites could outweigh the value of continually visiting a single site. Risk Mitigation is a major concern for initial human missions to Mars. There are a number of hazards related to operating on the Martian surface that are not well characterized. It may be desirable to conduct a series of short duration missions to better understand the nature of these risks prior to committing to a long duration mission. Developmental Affordability relates to the ability of NASA and its partners to develop and deploy the proposed architecture. Any human missions to Mars will be among the most complex endeavors ever undertaken. The capabilities that must be developed to enable any human Mars missions are extremely challenging. The total design, development, test, and evaluation (DDT&E) budget required to develop just the essential capabilities alone will be substantial. If additional surface capabilities are required to support long duration surface stays, the development effort could be unaffordable. Operational Affordability & Flexibility relates to the continued costs to execute the Mars campaign. Long duration missions, even with some amount of in-situ resource utilization, require a significant level of resupply for every mission. This requires additional launches and in-space transportation assets, increasing the operational complexity and total operational cost. This paper will explore each of the four potential advantages of short duration missions in detail. The authors will present comparisons between proposed long duration and short duration architectures through an evaluation of relevant performance, cost, and risk metrics.

Stromgren, Chel↗