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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and require extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk.

Nathaniel Olson↗
NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and require extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk.

Nathaniel Olson↗
NASA NTRS1991

Thermally isolated deployable shield for spacecraft

A thermally isolated deployable shield for spacecraft is provided utilizing a plurality of lattice panels stowable generally against the craft and deployable to some fixed distance from the craft. The lattice panels are formed from replaceable shield panels affixed to lattice structures. The lattice panels generally encircle the craft providing 360 degree coverage therearound. Actuation means are provided from translating the shield radially outward from the craft and thermally isolating the shield from the craft. The lattice panels are relatively flexible, allowing the shield to deploy to variable diameters while retaining uniform curvature thereof. Restraining means are provided for holding the shield relatively tight in its stowed configuration. Close-out assemblies provide light sealing and protection of the annular spaces between the deployed shield and the crafts end structure.

Redmon, John W., Jr.↗
NASA NTRS2006

Potential Polymeric Sphere Construction Materials for a Spacecraft Electrostatic Shield

An electrostatic shielding concept for spacecraft radiation protection under NASA s Exploration Systems Research and Technology Program was evaluated for its effectiveness and feasibility. The proposed shield design is reminiscent of a classic quadrupole with positively and negatively charged spheres surrounding the spacecraft. The project addressed materials, shield configuration, power supply, and compared its effectiveness to that of a passive shield. The report herein concerns the identification of commercially available materials that could be used in sphere fabrication. It was found that several materials were needed to potentially construct the spheres for an electrostatic shield operating at 300 MV.

Smith, Joseph G., Jr.↗
NASA NTRS2007

Foam Core Shielding for Spacecraft

A foam core shield (FCS) system is now being developed to supplant multilayer insulation (MLI) systems heretofore installed on spacecraft for thermal management and protection against meteoroid impacts. A typical FCS system consists of a core sandwiched between a face sheet and a back sheet. The core can consist of any of a variety of low-to-medium-density polymeric or inorganic foams chosen to satisfy application-specific requirements regarding heat transfer and temperature. The face sheet serves to shock and thereby shatter incident meteoroids, and is coated on its outer surface to optimize its absorptance and emittance for regulation of temperature. The back sheet can be dimpled to minimize undesired thermal contact with the underlying spacecraft component and can be metallized on the surface facing the component to optimize its absorptance and emittance. The FCS systems can perform better than do MLI systems, at lower mass and lower cost and with greater volumetric efficiency.

Adams, Marc↗
NASA NTRS2005

Asymmetric Electrostatic Radiation Shielding for Spacecraft

A paper describes the types, sources, and adverse effects of energetic-particle radiation in interplanetary space, and explores a concept of using asymmetric electrostatic shielding to reduce the amount of such radiation impinging on spacecraft. Typically, such shielding would include a system of multiple inflatable, electrically conductive spheres deployed in clusters in the vicinity of a spacecraft on lightweight structures that would maintain the spheres in a predetermined multipole geometry. High-voltage generators would maintain the spheres at potential differences chosen in conjunction with the multipole geometry so that the resulting multipole field would gradually divert approaching energetic atomic nuclei from a central region occupied by the spacecraft. The spheres nearest the center would be the most positive, so as to repel the positively charged impinging nuclei from the center. At the same time, the monopole potential of the overall spacecraft-and-shielding system would be made negative so as to repel thermal electrons. The paper presents results of computational simulations of energetic-particle trajectories and shield efficiency for a trial system of 21 spheres arranged in three clusters in an overall linear quadrupole configuration. Further development would be necessary to make this shielding concept practical.

Metzger, Philip T.↗
NASA NTRS1984

Theoretical analysis of infrared radiation shields of spacecraft

For a system of N diffuse, gray body radiation shields which view only adjacent surfaces and space, the net radiation method for enclosures has been used to formulate a system of linear, nonhomogeneous equations in terms of the temperatures to the fourth power of each surface in the coupled system of enclosures. The coefficients of the unknown temperatures in the system of equations are expressed in terms of configuration factors between adjacent surfaces and the emissivities. As an application, a system of four conical radiation shields for a spin stabilized STARPROBE spacecraft has been designed and analyzed with respect to variations of the cone half angles, the intershield spacings, and emissivities.

Shealy, D. L.↗
NASA NTRS1992

Preliminary design of a meteoroid/orbital debris shield system for a Mars mission spacecraft

A preliminary design of a spacecraft shield system to defeat meteoroids and orbital debris during a Mars mission is presented. The mission scenario is first defined in terms of stage times which include LEO, transit, low-Mars orbit, and Mars surface periods. The environment definitions for earth-orbital space debris, planetary meteoroids, and interplanetary meteoroids are next introduced. Shield system design approaches incorporate stochastic simulation, hydrocode analyses, hypervelocity impact testing, and optimization techniques. Structural design trades presented include spacecraft configuration, mission schedule, penetration risk, and total standoff distance between the bumper and wall.

Robinson, J. H.↗
NASA NTRS1992

Space crew radiation exposure analysis system based on a commercial stand-alone CAD system

Major improvements have recently been completed in the approach to spacecraft shielding analysis. A Computer-Aided Design (CAD)-based system has been developed for determining the shielding provided to any point within or external to the spacecraft. Shielding analysis is performed using a commercially available stand-alone CAD system and a customized ray-tracing subroutine contained within a standard engineering modeling software package. This improved shielding analysis technique has been used in several vehicle design projects such as a Mars transfer habitat, pressurized lunar rover, and the redesigned Space Station. Results of these analyses are provided to demonstrate the applicability and versatility of the system.

Appleby, Matthew H.↗
NASA NTRS2014

Effects of High-Density Impacts on Shielding Capability

Spacecraft are shielded from micrometeoroids and orbital debris (MMOD) impacts to meet requirements for crew safety and/or mission success. In the past, orbital debris particles have been considered to be composed entirely of aluminum (medium-density material) for the purposes of MMOD shielding design and verification. Meteoroids have been considered to be low-density porous materials, with an average density of 1 g/cu cm. Recently, NASA released a new orbital debris environment model, referred to as ORDEM 3.0, that indicates orbital debris contains a substantial fraction of high-density material for which steel is used in MMOD risk assessments [Ref.1]. Similarly, an update to the meteoroid environment model is also under consideration to include a high-density component of that environment. This paper provides results of hypervelocity impact tests and hydrocode simulations on typical spacecraft MMOD shields using steel projectiles. It was found that previous ballistic limit equations (BLEs) that define the protection capability of the MMOD shields did not predict the results from the steel impact tests and hydrocode simulations (typically, the predictions from these equations were too optimistic). The ballistic limit equations required updates to more accurately represent shield protection capability from the range of densities in the orbital debris environment. Ballistic limit equations were derived from the results of the work and are provided in the paper.

Christiansen, Eric L.↗
NASA NTRS2006

Deep Space Test Bed for Radiation Studies

A key factor affecting the technical feasibility and cost of missions to Mars or the Moon is the need to protect the crew from ionizing radiation in space. Some analyses indicate that large amounts of spacecraft shielding may be necessary for crew safety. The shielding requirements are driven by the need to protect the crew from Galactic cosmic rays (GCR). Recent research activities aimed at enabling manned exploration have included shielding materials studies. A major goal of this research is to develop accurate radiation transport codes to calculate the shielding effectiveness of materials and to develop effective shielding strategies for spacecraft design. Validation of these models and calculations must be addressed in a relevant radiation environment to assure their technical readiness and accuracy. Test data obtained in the deep space radiation environment can provide definitive benchmarks and yield uncertainty estimates of the radiation transport codes. The two approaches presently used for code validation are ground based testing at particle accelerators and flight tests in high-inclination low-earth orbits provided by the shuttle, free-flyer platforms, or polar-orbiting satellites. These approaches have limitations in addressing all the radiation-shielding issues of deep space missions in both technical and practical areas. An approach based on long duration high altitude polar balloon flights provides exposure to the galactic cosmic ray composition and spectra encountered in deep space at a lower cost and with easier and more frequent access than afforded with spaceflight opportunities. This approach also results in shorter development times than spaceflight experiments, which is important for addressing changing program goals and requirements.

Adams, James H.↗