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The thermal protection system (TPS) of the Space Shuttle Orbiter is described as well as the results of dynamic reponse studies conducted in support of the efforts to certify the TPS for flight. The ceramic Thermal Protection System consists of ceramic tiles bonded to felt pads which are in turn bonded to the Orbiter substructure to protect the aluminum substructure from the heat of reentry.
A control and protection system was developed for use with a paralleled 2.5-kWe-per-module static inverter-converter system. The control and protection system senses internal and external fault parameters such as voltage, frequency, current, and paralleling current unbalance. A logic system controls contactors to isolate defective power conditioners or loads. The system sequences contactor operation to automatically control parallel operation, startup, and fault isolation. Transient overload protection and fault checking sequences are included. The operation and performance of a control and protection system, with detailed circuit descriptions, are presented.
Thermal ice protection systems use heat energy to prevent a dangerous buildup of ice on an aircraft. As aircraft become more efficient, less heat energy is available to operate a thermal ice protections system. This requires that thermal ice protection systems be designed to more exacting standards so as to more efficiently prevent a dangerous ice buildup without adversely affecting aircraft safety. While the effects of altitude have always beeing taked into account in the design of thermal ice protection systems, a better understanding of these effects is needed so as to enable more exact design, testing, and evaluation of these systems.
The Space Launch System (SLS) Core Stage base heat shield experienced the highest external heating environments on the entire launch vehicle during Artemis I ascent flight. This result was consistent with design predictions. The base heat shield experiences P50 cork combustion dynamics at low altitudes, plume-induced recirculation at moderate altitudes and then in-space base flow physics out to Main Engine Cut-Off (MECO). The base heat shield thermal protection system (TPS) is composed of a P50 cork ablator which is bonded to a substrate. The heat shield protects the gimbal actuation system, RS-25 turbomachinery systems and other aft section sensitive components during ascent. This paper estimates the base heat shield TPS performance from Artemis I using flight data from the NASA Langley Research Center’s Scientifically Calibrated In-Flight Imagery (SCIFLI) Airborne Multispectral Imager (SAMI), development flight instrumentation (DFI) and other TPS recession flight measurements. Predictions from computational and ground test-derived engineering ablation models and observations are also applied. Since no base heat shield substrate thermocouple data were obtained for Artemis I, an estimate of the TPS performance data is derived here. This data assesses thermal margin of the SLS Core Stage base heat shield and best informs the Artemis II Crewed mission to the moon.
Ablative thermal protection systems are commonly used as protection from the intense heat during re-entry of a space vehicle and have been used successfully on many missions including Stardust and Mars Science Laboratory both of which used PICA - a phenolic based ablator. Historically, phenolic resin has served as the ablative polymer for many TPS systems. However, it has limitations in both processing and properties such as char yield, glass transition temperature and char stability. Therefore alternative high performance polymers are being considered including cyanate ester resin, polyimide, and polybenzoxazine. Thermal and mechanical properties of these resin systems were characterized and compared with phenolic resin.
Interest in thermal protection systems for high-speed vehicles is increasing because of the stringent requirements of such new projects as the Space Exploration Initiative, the National Aero-Space Plane, and the High-Speed Civil Transport, as well as the needs for improved capabilities in existing thermal protection systems in the Space Shuttle and in turbojet engines. This selection of 13 papers from NASA and industry summarizes the history and operational experience of thermal protection systems utilized in the national space program to date, and also covers recent development efforts in thermal insulation, refractory materials and coatings, actively cooled structures, and two-phase thermal control systems.
A metallic thermal protection system (TPS) concept the multiwall designed for temperature and pressure at Shuttle body point 3140 where the maximum surface temperature is approximately 811 K was tested to evaluate thermal performance and structural integrity. A two tile model of titanium multiwall and a model consisting of a low temperature reusable surface insulation (LRSI) tiles were exposed to 25 simulated thermal and pressure Shuttle entry missions. The two systems performed the same, and neither system deteriorated during the tests. It is indicated that redesign of the multiwall tiles reduces tile thickness and/or weight. A nine tile model of titanium multiwal was tested for radiant heating and aerothermodynamics. Minor design changes that improve structural integrity without having a significant impact on the thermal protection ability of the titanium multiwall TPS are identified. The capability of a titanium multiwall thermal protection system to protect an aluminum surface during a Shuttle type entry trajectory at locations on the vehicle where the maximum surface temperature is below 811 K is demonstrated.
Atmospheric entry vehicle thermal protection systems are margined due to the uncertainties that exist in entry aeroheating environments and the thermal response of the materials and structures. Entry vehicle thermal protections systems are traditionally over-margined for the heat loads that are experienced along the entry trajectory by designing to survive stacked worst-case scenarios. Additionally, the conventional heat shield design and margin process offers very little insight into the risk of over-temperature during flight and the corresponding reliability of the heat shield performance. A probabilistic margin process can be used to appropriately margin the thermal protection system based on rigorously calculated risk of failure. This probabilistic margin process allows engineers to make informed aeroshell design, entry-trajectory design, and risk trades while preventing excessive margin from being applied. This study presents the methods of the probabilistic margin process and how the uncertainty analysis is used to determine the reliability of the entry vehicle thermal protection system and associated risks of failure.
Biological thiols are essential elements in most aspects of cell function but undergo rapid oxidation to disulfides in the presence of oxygen. The evolution of systems to protect against such oxygen toxicity was essential to the emergence of aerobic life. The protection system used by eukaryotes is based upon glutathione (GSH) and GSH-dependent enzymes but many bacteria lack GSH and apparently use other mechanisms. The objective of this research is to elaborate the thiol protective mechanisms employed by prokaryotes of widely divergent evolutionary origin and to understand why GSH became the central thiol employed in essentially all higher organisms. Thiol-selective fluorescent labeling and HPLC analysis has been used to determine key monothiol components.
This research concentrated on the application of advanced signal processing, expert system, and digital technologies for the detection and control of low grade, incipient faults on spaceborne power systems. The researchers have considerable experience in the application of advanced digital technologies and the protection of terrestrial power systems. This experience was used in the current contracts to develop new approaches for protecting the electrical distribution system in spaceborne applications. The project was divided into three distinct areas: (1) investigate the applicability of fault detection algorithms developed for terrestrial power systems to the detection of faults in spaceborne systems; (2) investigate the digital hardware and architectures required to monitor and control spaceborne power systems with full capability to implement new detection and diagnostic algorithms; and (3) develop a real-time expert operating system for implementing diagnostic and protection algorithms. Significant progress has been made in each of the above areas. Several terrestrial fault detection algorithms were modified to better adapt to spaceborne power system environments. Several digital architectures were developed and evaluated in light of the fault detection algorithms.
There exists an infrequent, but significant hazard to life and property due to impacting asteroids and comets. There is currently no specific search for long-period comets, smaller near-Earth asteroids, or smaller short-period comets. These objects represent a threat with potentially little or no warning time using conventional ground-based telescopes. These planetary bodies also represent a significant resource for commercial exploitation, long-term sustained space exploration, and scientific research. The Comet/Asteroid Protection System (CAPS) would expand the current detection effort to include long-period comets, as well as small asteroids and short-period comets capable of regional destruction. A space-based detection system, despite being more costly and complex than Earth-based initiatives, is the most promising way of expanding the range of detectable objects, and surveying the entire celestial sky on a regular basis. CAPS is a future spacebased system concept that provides permanent, continuous asteroid and comet monitoring, and rapid, controlled modification of the orbital trajectories of selected bodies. CAPS would provide an orbit modification system capable of diverting kilometer class objects, and modifying the orbits of smaller asteroids for impact defense and resource utilization. This paper provides a summary of CAPS and discusses several key areas and technologies that are being investigated.
The Thermal Protection System (TPS) for the Shuttle/Centaur had to provide fail-safe thermal protection during prelaunch, launch ascent, and on-orbit operations as well as during potential abort where the Shuttle and Centaur would return to earth. The TPS selected used a helium-purged polyimide foam beneath three radiation shields for the liquid hydrogen (LH2) tank and radiation shields only for the liquid oxygen (LO2) tank (three shields on the tank sidewall and four on the aft bulkhead). An evacuated common intermediate bulkhead separated the two tanks. The LH2 tank had one 1.9-cm thick layer of foam on the forward bulkhead and two layers on the larger area side-wall. Full scale tests of the flight vehicle in a simulated Shuttle cargo bay, that was purged with gaseous nitrogen, gave total prelaunch heating rates of 25.9 kW and 12.9 kW for LH2 and LO2 tanks, respectively. Calorimeter tests on a representative LH2 tank sidewall TPS sample indicated that the measured unit heating rate would rapidly decrease from the prelaunch rate of 300 W/sq m to a desired rate of less than 4 W/sq m once on-orbit.
The thermal protection systems (TPS) for the Shuttle/Centaur were designed to provide fail-safe thermal protection during prelaunch, launch ascent, and on-orbit operations as well as during potential abort, where the Shuttle and Centaur would return to earth. The TPS selected used a helium-purged polyimide foam beneath three radiation shields for the liquid-hydrogen (LH2) tank and radiation shields only for the liquid-oxygen (LO2) tank. A double-walled vacuum bulkhead separated the two tanks. The LH2 tank had one 1.9 cm-thick layer of foam on the forward bulkhead and two layers on the larger-area sidewall. Full scale tests of the flight vehicle in a simulated Shuttle cargo bay gave total prelaunch heating rates of 29.5 and 12.9 kW for the LH2 and LO2 tanks, respectively. Calorimeter tests on a representative sample of the LH2 tank sidewall TPS indicated that the measured unit heating one would rapidly decrease from the prelaunch rate of about 300 W/sq m to a desired rate less than 4 W/sq m once on-orbit.
The Thermal Protection System Materials (TPSM) Project consists of three distinct project elements: the 3-Dimensional Multifunctional Ablative Thermal Protection System (3D MAT) project element; the Conformal Ablative Thermal Protection System (CA-TPS) project element; and the Heatshield for Extreme Entry Environment Technology (HEEET) project element. 3D MAT seeks to design, develop and deliver a game changing material solution based on 3-dimensional weaving and resin infusion approach for manufacturing a material that can function as a robust structure as well as a thermal protection system. CA-TPS seeks to develop and deliver a conformal ablative material designed to be efficient and capable of withstanding peak heat flux up to 500 W/ sq cm, peak pressure up to 0.4 atm, and shear up to 500 Pa. HEEET is developing a new ablative TPS that takes advantage of state-of-the-art 3D weaving technologies and traditional manufacturing processes to infuse woven preforms with a resin, machine them to shape, and assemble them as a tiled solution on the entry vehicle substructure or heatshield.
Ablative thermal protection system for Apollo command module
Protective coatings for heat resistant materials for aircraft gas turbine engines, and refractory metals for reentry vehicles
Overload protection circuit utilizes one circuit for suspending inverter action when load abnormality is detected and second circuit to monitor clearance of abnormality. Device wastes no power during normal operating conditions and responds instantaneously when abnormality is cleared.
Bowing of metallic thermal protection systems for reentry of a previously proposed single-stage-to-orbit reusable launch vehicle was studied. The outer layer of current metallic thermal protection system concepts typically consists of a honeycomb panel made of a high temperature nickel alloy. During portions of reentry when the thermal protection system is exposed to rapidly varying heating rates, a significant temperature gradient develops across the honeycomb panel thickness, resulting in bowing of the honeycomb panel. The deformations of the honeycomb panel increase the roughness of the outer mold line of the vehicle, which could possibly result in premature boundary layer transition, resulting in significantly higher downstream heating rates. The aerothermal loads and parameters for three locations on the centerline of the windward side of this vehicle were calculated using an engineering code. The transient temperature distributions through a metallic thermal protection system were obtained using 1-D finite volume thermal analysis, and the resulting displacements of the thermal protection system were calculated. The maximum deflection of the thermal protection system throughout the reentry trajectory was 6.4 mm. The maximum ratio of deflection to boundary layer thickness was 0.032. Based on previously developed distributed roughness correlations, it was concluded that these defections will not result in tripping the hypersonic boundary layer.