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All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Method for Fabricating Composite Structures Using Pultrusion Processing

A method for fabricating composite structures at a low-cost, moderate-to-high production rate. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform and debulking the partially debulked preform to form a net-shape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length and electron-beam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates, resulting in lower cost and high structural performance.

Farley, Gary L.↗
NASA NTRS1997

Passive Microwave Observation of Soil Water Infiltration

Infiltration is a time varying process of water entry into soil. Experiments were conducted here using truck based microwave radiometers to observe small plots during and following sprinkler irrigation. Experiments were conducted on a sandy loam soil in 1994 and a silt loam in 1995. Sandy loam soils typically have higher infiltration capabilities than clays. For the sandy loam the observed brightness temperature (TB) quickly reached a nominally constant value during irrigation. When the irrigation was stopped the TB began to increase as drainage took place. The irrigation rates in 1995 with the silt loam soil exceeded the saturated conductivity of the soil. During irrigation the TB values exhibited a pattern that suggests the occurrence of coherent reflection, a rarely observed phenomena under natural conditions. These results suggested the existence of a sharp dielectric boundary (wet over dry soil) that was increasing in depth with time.

Jackson, Thomas J.↗
NASA NTRS2007

Strengthening Aluminum Alloys for High Temperature Applications Using Nanoparticles of Al203 and Al3-X Compounds (X= Ti, V, Zr)

In this paper the effect of nanoparticles A12O3 and A13-X compounds (X= Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their chemical stability and low diffusions rates in aluminum matrix at high temperatures. The strengthening mechanism for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. Samples were prepared from A12O3 nanoparticle preforms, which were produced using ceramic injection molding process and pressure infiltrated by molten aluminum. A12O3 nanoparticles can also be homogeneously mixed with aluminum powder and consolidated into samples through hot pressing and sintering. On the other hand, the Al3-X nanoparticles are produced as precipitates via in situ reactions with molten aluminum alloys using conventional casting techniques. The degree of alloy strengthening using nanoparticles will depend on the materials, particle size, shape, volume fraction, and mean inter-particle spacing.

Lee, Jonathan A.↗
NASA NTRS1997

Subacute diabetic proximal neuropathy

OBJECTIVE: To evaluate the clinical, electrophysiologic, autonomic, and neuropathologic characteristics and the natural history of subacute diabetic proximal neuropathy and its response to immunotherapy. MATERIAL AND METHODS: For the 12-year period from 1983 to 1995, we conducted a retrospective review of medical records of Mayo Clinic patients with diabetes who had subacute onset and progression of proximal weakness. The responses of treated versus untreated patients were compared statistically. RESULTS: During the designated study period, 44 patients with subacute diabetic proximal neuropathy were encountered. Most patients were middle-aged or elderly, and no sex preponderance was noted. The proximal muscle weakness often was associated with reduced or absent lower extremity reflexes. Associated weight loss was a common finding. Frequently, patients had some evidence of demyelination on nerve conduction studies, but it invariably was accompanied by concomitant axonal degeneration. The cerebrospinal fluid protein concentration was usually increased. Diffuse and substantial autonomic failure was generally present. In most cases, a sural nerve biopsy specimen suggested demyelination, although evidence of an inflammatory infiltrate was less common. Of 12 patients who received treatment (with prednisone, intravenous immune globulin, or plasma exchange), 9 had improvement of their conditions, but 17 of 29 untreated patients (59%) with follow-up also eventually had improvement, albeit at a much slower rate. Improvement was usually incomplete. CONCLUSION: We suggest that the entity of subacute diabetic proximal neuropathy is an extensive and severe variant of bilateral lumbosacral radiculoplexopathy, with some features suggestive of an immune-mediated cause. It differs from chronic inflammatory demyelinating polyradiculoneuropathy in that most cases have a more restricted distribution and seem to be monophasic and self-limiting. The efficacy of immunotherapy is unproved, but such intervention may be considered in the severe and progressive cases or ones associated with severe neuropathic pain.

Non-NASA Center↗
NASA NTRS2002

Bn and Si-Doped Bn Coatings on Woven Fabrics

A computer controlled, pulsed chemical vapor infiltration (CVI) system has been developed to deposit BN from a liquid borazine (B3N3H6) source, as well as silicon doped BN coatings using borazine and a silicon source, into 2-D woven ceramic fabric preforms. The coating process was evaluated as a function of deposition temperature, pressure, and precursor flow rate. Coatings were characterized by field emission scanning electron microscopy, electron dispersive spectroscopy and Auger spectroscopy. By controlling the reactant feed ratios, Si incorporation could be controlled over the range of 6-24 atomic percent.

Hurwitz, Frances I.↗
NASA NTRS2009

Cast Aluminum Alloys for High Temperature Applications Using Nanoparticles Al2O3 and Al3-X Compounds (X = Ti, V, Zr)

In this paper, the effect of nanoparticles Al2O3 and Al3-X compounds (X = Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their low cost, chemical stability and low diffusions rates in aluminum at high temperatures. The strengthening mechanism at high temperature for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. For Al2O3 nanoparticles, the test samples were prepared from special Al2O3 preforms, which were produced using ceramic injection molding process and then pressure infiltrated by molten aluminum. In another method, Al2O3 nanoparticles can also be homogeneously mixed with fine aluminum powder and consolidated into test samples through hot pressing and sintering. With the Al3-X nanoparticles, the test samples are produced as precipitates from in-situ reactions with molten aluminum using conventional permanent mold or die casting techniques. It is found that cast aluminum alloy using nanoparticles Al3-X is the most cost effective method to produce high strength aluminum alloys for high temperature applications in comparison to nanoparticles Al2O3. Furthermore, significant mechanical properties retention in high temperature environment could be achieved with Al3-X nanoparticles, resulting in tensile strength of nearly 3 times higher than most 300- series conventional cast aluminum alloys tested at 600 F.

Lee, Jonathan A.↗
NASA NTRS1982

Comparison between the weightlessness syndrome and aging

The similarity of detrimental effects of normal aging and of exposure to space weightlessness is discussed. The effects include: the reduction in cardiac output, increase in blood pressure, decrease in respiratory vital capacity, decrease in lean body weight and muscle mass, collagen and fat infiltration of muscle, bone demineralization, and a decrease in urinary excretion of total 17-hydroxicorticosteroids. It is also noted that dispite the accelerated aging of organisms, if animals or human subjects were to spend their entire lives in weightlessness, their lifespans might be significantly increased because of a reduction in metabolic rate. Experimental results are cited.

Miquel, J.↗
NASA NTRS1993

Marked point process models of raindrop-size distributions

The principal process considered in this paper is the flux of raindrops through a volume of the atmosphere. This process is of fundamental importance for a wide variety of engineering and environmental problems, notably remote sensing of precipitation, infiltration of rainfall, soil erosion, atmospheric deposition of pollutants, and design of microwave communication systems. A marked point process model is developed in which the point process represents the arrival times of drops at the upper surface of a sample volume and the mark associated with a drop is its diameter. In the model, both the rate of occurrence of raindrops and the distribution of drop diameters vary randomly over time. Results that relate the drop-size distribution within the sample volume to the probability law of the drop-arrival process are presented. These results allow straightforward comparisons between temporal characterizations of drop-size distributions and spatial characterizations. Representations for derived processes such as rainfall rate and reflectivity are shown to be quite accurate using raindrop data from North Carolina.

Smith, James A.↗
NASA NTRS2021

Modeling Snow Ablation over the Western United States Mountains: Patterns and Controlling Factors

When compared with differences in snow accumulation predicted by widely used hydrological models, there is a much greater divergence among otherwise “good” models in their simulation of the snow ablation process. Here, we explore differences in the performance of the Variable Infiltration Capacity model (VIC), Noah land surface model with multiparameterization options (Noah-MP), the Catchment model, and the third-generation Simplified Simple Biosphere model (SiB3) in their ability to reproduce observed snow water equivalent (SWE) during the ablation season at 10 Snowpack Telemetry (SNOTEL) stations over 1992–2012. During the ablation period, net radiation generally has stronger correlations with observed melt rates than does air temperature. Average ablation rates tend to be higher (in both model predictions and observations) at stations with a large accumulation of SWE. The differences in the dates of last snow between models and observations range from several days to approximately a month (on average 5.1 days earlier than in observations). If the surface cover in the models is changed from observed vegetation to bare soil in all of the models, only the melt rate of the VIC model increases. The differences in responses of models to canopy removal are directly related to snowpack energy inputs, which are further affected by different algorithms for surface albedo and energy allocation across the models. We also find that the melt rates become higher in VIC and lower in Noah-MP if the shrub/grass present at the observation sites is switched to trees.

Snow↗
NASA NTRS1976

Carbide coated fibers in graphites-aluminum composites

Research activities are described for a NASA-supported program at the Los Alamos Scientific Laboratory to develop graphite fiber-aluminum matrix composites. A chemical vapor deposition apparatus was constructed for continuously coating graphite fibers with TiC. As much as 150 meters of continuously coated fibers were produced. Deposition temperatures were varied from 1365 K to about 1750 K, and deposition time from 6 to 150 seconds. The 6 sec deposition time corresponded to a fiber feed rate of 2.54 m/min through the coater. Thin, uniform, adherent TiC coats, with thicknesses up to approximately 0.1 micrometer were produced on the individual fibers of Thornel 50 graphite yarns without affecting fiber strength. Although coat properties were fairly uniform throughout a given batch, more work is needed to improve the batch-to-batch reproducibility. Samples of TiC-coated Thornel 50 fibers were infiltrated with an aluminum alloy and hot-pressed in vacuum to produce small composite bars for flexure testing. Strengths as high as 90% of the rule-of-mixtures strength were achieved. Results of the examination of the fracture surfaces indicate that the bonding between the aluminum and the TiC-coated fibers is better than that achieved in a similar, commercially infiltrated material made with fibers having no observable surface coats. Several samples of Al-infiltrated, TiC-coated Thornel 50 graphite yarns, together with samples of the commercially infiltrated, uncoated fibers, were heated for 100 hours at temperatures near the alloy solidus. The TiC-coated samples appear to undergo less reaction than do the uncoated samples. Photomicrographs are shown.

Imprescia, R. J.↗
NASA NTRS1995

Development of an in-line filter to prevent intrusion of NO2 toxic vapors into A/C systems

The hypergolic propellant nitrogen tetroxide (N2O4 or NTO) is routinely used in spacecraft launched at Kennedy Space Center (KSC) and Cape Canaveral Air Station (CCAS). In the case of a catastrophic failure of the spacecraft, there would be a release of the unspent propellant in the form of a toxic cloud. Inhalation of this material at downwind concentrations which may be as high as 20 parts per million (ppm) for 30 minutes in duration, may produce irritation to the eyes, nose and respiratory tract. Studies at both KSC and CCAS have shown that the indoor concentrations of N2O4 during a toxic release may range from 1 to 15 ppm and depend on the air change rate (ACR) for a particular building and whether or not the air conditioning (A/C) system has been shut down or left in an operating mode. This project was initiated in order to assess how current A/C systems could be easily modified to prevent personnel from being exposed to toxic vapors. A sample system has been constructed to test the ability of several types of filter material to capture the N2O4 vapors prior to their infiltration into the A/C system. Test results will be presented which compare the efficiencies of standard A/C filters, water wash systems, and chemically impregnated filter material in taking toxic vapors out of the incoming air stream.

Meneghelli, Barry↗
NASA NTRS1990

Technique for assessing vegetation-induced moisture flux, with implications for global climate modeling

The time between storms, the duration of storms, and the storm depths are studied in relation to vegetation controls on the disposition of rainfall. It is proposed that understanding the movement of water between the vegetation and soil (including evapotranspiration and infiltration) will be the gateway for modeling atmospheric flux and improving global climate models. The overall objective goal of the proposed research effort is to develop a field/lab methodology which will provide a better understanding of vegetation induced water movement. Water flow initiated from stem flow of wooded slopes feeds soil water pathways, which in turn feed the deeper ground water system and give rise to stream response. This is balanced by more water inputs via throughfall, where it percolates the soil matrix and allows much greater rates of evapotranspiration and atmospheric/soil moisture flux. This research study seeks to gain an understanding of the effect of vegetation on soil moisture, and the effect of this differential wetting on resulting evapotranspiration and atmospheric flux.

Macari, Emir Jose↗
NASA NTRS2013

High-Pressure Lightweight Thrusters

Returning samples of Martian soil and rock to Earth is of great interest to scientists. There were numerous studies to evaluate Mars Sample Return (MSR) mission architectures, technology needs, development plans, and requirements. The largest propulsion risk element of the MSR mission is the Mars Ascent Vehicle (MAV). Along with the baseline solid-propellant vehicle, liquid propellants have been considered. Similar requirements apply to other lander ascent engines and reaction control systems. The performance of current state-ofthe- art liquid propellant engines can be significantly improved by increasing both combustion temperature and pressure. Pump-fed propulsion is suggested for a single-stage bipropellant MAV. Achieving a 90-percent stage propellant fraction is thought to be possible on a 100-kg scale, including sufficient thrust for lifting off Mars. To increase the performance of storable bipropellant rocket engines, a high-pressure, lightweight combustion chamber was designed. Iridium liner electrodeposition was investigated on complex-shaped thrust chamber mandrels. Dense, uniform iridium liners were produced on chamber and cylindrical mandrels. Carbon/carbon composite (C/C) structures were braided over iridium-lined mandrels and densified by chemical vapor infiltration. Niobium deposition was evaluated for forming a metallic attachment flange on the carbon/ carbon structure. The new thrust chamber was designed to exceed state-of-the-art performance, and was manufactured with an 83-percent weight savings. High-performance C/Cs possess a unique set of properties that make them desirable materials for high-temperature structures used in rocket propulsion components, hypersonic vehicles, and aircraft brakes. In particular, more attention is focused on 3D braided C/Cs due to their mesh-work structure. Research on the properties of C/Cs has shown that the strength of composites is strongly affected by the fiber-matrix interfacial bonding, and that weakening interface realizes pseudo-plastic behavior with significant increase in the tensile strength. The investigation of high-temperature strength of C/Cs under high-rate heating (critical for thrust chambers) shows that tensile and compression strength increases from 70 MPa at room temperature to 110 MPa at 1,773 K, and up to 125 MPa at 2,473 K. Despite these unique properties, the use of C/Cs is limited by its high oxidation rate at elevated temperatures. Lining carbon/carbon chambers with a thin layer of iridium or iridium and rhenium is an innovative way to use proven refractory metals and provide the oxidation barrier necessary to enable the use of carbon/ carbon composites. Due to the lower density of C/Cs as compared to SiC/SiC composites, an iridium liner can be added to the C/C structure and still be below the overall thruster weight. Weight calculations show that C/C, C/C with 50 microns of Ir, and C/C with 100 microns of Ir are of less weight than alternative materials for the same construction.

Holmes, Richard↗
NASA NTRS2022

Simulations of Firn Processes Over the Greenland and Antarctic Ice Sheets: 1980-2021

Conversion of altimetry-derived ice-sheet volume change to mass requires an understanding of the evolution of the combined ice and air content within the firn column. In the absence of suitable techniques to observe the changes to the firn column across the entirety of an ice sheet, the firn column processes are typically modeled. Here, we present new simulations of firn processes over the Greenland and Antarctic ice sheets (GrIS and AIS) using the Community Firn Model and atmospheric reanalysis variables for more than four decades. A data set of more than 250 measured depth–density profiles from both ice sheets provides the basis of the calibration of the dry-snow densification scheme. The resulting scheme results in a reduction in the rate of densification, relative to a commonly used semi-empirical model, through a decreased dependence on the accumulation rate, a proxy for overburden stress. The 1980–2020 modeled firn column runoff, when combined with atmospheric variables from MERRA-2, generates realistic mean integrated surface mass balance values for the Greenland (+390 Gt yr(exp −1)) and Antarctic (+2612 Gt yr(exp −1)) ice sheets when compared to published model-ensemble means. We find that seasonal volume changes associated with firn air content are on average approximately 2.5 times larger than those associated with mass fluxes from surface processes for the AIS and 1.5 times larger for the GrIS; however, when averaged over multiple years, ice and air-volume fluctuations within the firn column are of comparable magnitudes. Between 1996 and 2019, the Greenland Ice Sheet lost nearly 5% of its firn air content, indicating a reduction in the total meltwater retention capability. Nearly all (94 %) of the meltwater produced over the Antarctic Ice Sheet is retained within the firn column through infiltration and refreezing.

Greenland↗
NASA NTRS1999

Intermediate Temperature Stress Rupture of a Woven Hi-Nicalon, BN-Interphase, SiC Matric Composite in Air

Woven Hi-Nicalon (TM) reinforced melt-infiltrated SiC matrix composites were tested under tensile stress-rupture conditions in air at intermediate temperatures. A comprehensive examination of the damage state and the fiber properties at failure was performed. Modal acoustic emission analysis was used to monitor damage during the experiment. Extensive microscopy of the composite fracture surfaces and the individual fiber fracture surfaces was used to determine the mechanisms leading to ultimate failure. The rupture properties of these composites were significantly worse than expected compared to the fiber properties under similar conditions. This was due to the oxidation of the BN interphase. Oxidation occurred through the matrix cracks that intersected the surface or edge of a tensile bar. These oxidation reactions resulted in minor degradation to fiber strength and strong bonding of the fibers to one another at regions of near fiber-to-fiber contact. It was found that two regimes for rupture exist for this material: a high stress regime where rupture occurs at a fast rate and a low stress regime where rupture occurs at a slower rate. For the high stress regime, the matrix damage state consisted of through thickness cracks. The average fracture strength of fibers that were pulled-out (the final fibers to break before ultimate failure) was controlled by the slow-crack growth rupture criterion in the literature for individual Hi-Nicalon (TM) fibers. For the low stress regime, the matrix damage state consisted of microcracks which grew during the rupture test. The average fracture strength of fibers that were pulled-out in this regime was the same as the average fracture strength of individual fibers pulled out in as-produced composites tested at room temperature.

Morscher, Gregory N.↗
NASA NTRS2018

Seasonal Monitoring of Melt and Accumulation Within the Deep Percolation Zone of the Greenland Ice Sheet and Comparison with Simulations of Regional Climate Modeling

Increasing melt over the Greenland Ice Sheet (GrIS) recorded over the past several years has resulted in significant changes of the percolation regime of the ice sheet. It remains unclear whether Greenland's percolation zone will act as a meltwater buffer in the near future through gradually filling all pore space or if near-surface refreezing causes the formation of impermeable layers, which provoke lateral runoff. Homogeneous ice layers within perennial firn, as well as near-surface ice layers of several meter thickness have been observed in firn cores. Because firn coring is a destructive method, deriving stratigraphic changes in firn and allocation of summer melt events is challenging. To overcome this deficit and provide continuous data for model evaluations on snow and firn density, temporal changes in liquid water content and depths of water infiltration, we installed an upward-looking radar system (upGPR) 3.4 m below the snow surface in May 2016 close to Camp Raven (66.4779 deg N, 46.2856 deg W) at 2120 m a.s.l. The radar is capable of quasi-continuously monitoring changes in snow and firn stratigraphy, which occur above the antennas. For summer 2016, we observed four major melt events, which routed liquid water into various depths beneath the surface. The last event in mid-August resulted in the deepest percolation down to about 2.3 m beneath the surface. Comparisons with simulations from the regional climate model MAR are in very good agreement in terms of seasonal changes in accumulation and timing of onset of melt. However, neither bulk density of near-surface layers nor the amounts of liquid water and percolation depths predicted by MAR correspond with upGPR data. Radar data and records of a nearby thermistor string, in contrast, matched very well for both timing and depth of temperature changes and observed water percolations. All four melt events transferred a cumulative mass of 56 kg/(sq. m) into firn beneath the summer surface of 2015. We find that continuous observations of liquid water content, percolation depths and rates for the seasonal mass fluxes are sufficiently accurate to provide valuable information for validation of model approaches and help to develop a better understanding of liquid water retention and percolation in perennial firn.

Heilig, Achim↗
NASA NTRS2014

Conformal Ablative Thermal Protection System for Planetary and Human Exploration Missions: An Update of the Technology Maturation Effort

This presentation will update the community on the development of conformal ablative TPS. 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 downselecting, 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 downselected 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).

thermal protection systems↗
NASA NTRS2014

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↗