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At least 361 records · Page 20

Updates to the Predictive Materials Modeling Software Tools

Updates on NASA's efforts to build predictive material models from the micro-scale to the macro-scale are presented. To complement the mission design cycle process and reduce the need for extensive testing, NASA is developing modeling and simulation tools that enable characterizing material properties and response to hot plasma experienced during atmospheric entry. The PuMA (microstructure analysis), PATO (macroscale material response), SPARTA (direct simulation Monte Carlo) and ARCHeS (arc heater modeling) codes are described. A range of applications, encompassing calculating effective material properties, study of high shear boundary layer flow over woven materials, new model of silicone-based coatings, new model of mechanical erosion, as well as approach to loose multi-physics coupling, are presented.

material modeling↗

Validating Drag and Heating Coefficients for Hollow Reentry Objects in Continuum Flow Using a Mach 7 Ludwieg Tube

Drag and heating coefficient databases and models are crucial to destructive reentry simulation. The NASA Orbital Debris Program Office (ODPO) develops, maintains, and performs analysis with the Object Reentry Survival Analysis Tool (ORSAT), which comprises drag and heating models for free molecular, transitional, and continuum flow regimes. These models have, in the past, only included solid, convex, blunt shapes (such as boxes, spheres, and cylinders). Previous work led by ODPO includes the extension of these models to hollow cylinders and square boxes in free molecular and transitional flow using the Direct Simulation Monte Carlo (DSMC) method. Since 2019, the ODPO has continued its program of DSMC simulations and extended the project to include analyses with the NASA Data Parallel Line Relaxation (DPLR) program on hollow cylinders and boxes (with varying wall thickness-diameter ratio). In fall 2022, the ODPO began a collaboration with the University of Texas San Antonio (UTSA) to use the Mach 7 Ludwieg Tube facility to validate the model built using numerical simulations. This facility can replicate (at a scale of approximately 100:1) the conditions seen by reentering objects near typical demise altitudes. We present here the drag and heating coefficients derived from the continued DSMC simulations, the new DPLR simulations, and the 26-test series at UTSA.

Chris Ostrom↗

Recent Updates to the Object Reentry Survival Analysis Tool (ORSAT) Version 7.1

The Object Reentry Survival Analysis Tool (ORSAT) code is maintained and used by the NASA Orbital Debris Program Office (ODPO) and has been under continuous development and improvement since the mid-1990s. ORSAT is an object-oriented reentry simulation tool; it models a satellite as a collection of discrete components that follow independent trajectories upon the breakup of the parent object. Version 7.1 of the tool incorporates five years of new thermal and aerodynamic model development, multi-processor parametric study capability, codebase upgrades, and numerous bug-fixes. The thermal demise model was completely rewritten using a forward-time/central-space numerical stencil and incorporating a new pyrolysis model for fiber-reinforced plastic (FRP) materials. New aerodynamic and aeroheating models for hollow cylinders and hollow square prisms were developed using a combination of flow simulations in the direct simulation Monte Carlo (DSMC) Analysis Code (DAC) and Data Parallel Line Relaxation (DPLR) code and free-flight tests in the University of Texas at San Antonio’s Hypersonic Wind Tunnel. The latest version also incorporates a mechanical, strength-based demise model for FRP materials. Minor improvements include an update to the Fortran 2018 codebase; improved integration and speed with the Python-based, multi-core, parametric study tool, AutoORSAT; and fixes for many minor bugs. This new version of ORSAT will enable more accurate reentry risk assessments for modern satellites. This paper presents an overview of these changes and a summary of the verification and validation performed on the final code.

Benton R. Greene↗

Comparison Between DSMC and CFD for Hypersonic Planetary Entry Simulations

Hypersonic planetary entry flows span a wide range of Knudsen numbers between rarefied and continuum flows. While computational fluid dynamics (CFD) techniques cannot provide an accurate solution for flows in the rarefied regime, the direct simulation Monte Carlo (DSMC) method is capable of providing accurate solutions for flows in both in the rarefied and continuum regimes but becomes prohibitively expensive as the Knudsen number decreases. For the purpose of thermal protection systems (TPS) design and post-flight reconstruction, various selected points along an entry trajectory are often solved using hypersonic solvers. The quantities of interest that are obtained from that exercise are generally surface quantities, such as pressure, heat flux and enthalpy. Then, material response solvers are used to either design the heat shield to an optimal thickness based on a choice of material, or to provide in-depth heating profiles through the material at various select locations, and compare with flight instrumentation such as the ones that flew on NASA’s two most recent Mars missions, MSL and Mars2020. While most of the heating is generally experienced during the continuum part of the entry, the heating within the rarefied regime is significant for some atmospheres, and hence the flow solutions need to be computed using the DSMC method. Ensuring consistency between hypersonic CFD and the DSMC is crucial so that reliable surface quantities can be passed to material response solvers. Studies were performed to compare the two methods at various select locations, for both non-reacting argon flows as well reacting CO2/N2 flows. Preliminary conclusions show that, for non-reacting flows, the agreement between the two methods for surface heating is excellent (within expected uncertainties) for a freestream Knudsen number of 0.0006, and gets progressively worse as the Knudsen number increases to 0.06. Continuum breakdown analyses were performed and showed that, in general, the Gradient Length Local Knudsen number (KnGLL) from Boyd [1] and associated criteria (KnGLL > 0.05) can be accurately used to predict zones of breakdown in the flow, and associated errors for surface quantities. Furthermore, when studying reacting flow, our studies showed that while flow quantities are highly dependent on relaxation parameters and chemistry rates, it is possible to obtain a good agreement for surface heating, as long as the continuum breakdown in minimal (see Fig. 1). Finally, we studied the impact of the grid refinement on the surface quantities in DSMC.

DSMC↗

Comparison Between DSMC and CFD for Hypersonic Planetary Entry Simulations

Hypersonic planetary entry flows span a wide range of Knudsen numbers between rarefied and continuum flows. While computational fluid dynamics (CFD) techniques cannot provide an accurate solution for flows in the rarefied regime, the direct simulation Monte Carlo (DSMC) method is capable of providing accurate solutions for flows in both in the rarefied and continuum regimes but becomes prohibitively expensive as the Knudsen number decreases. For the purpose of thermal protection systems (TPS) design and post-flight reconstruction, various selected points along an entry trajectory are often solved using hypersonic solvers. The quantities of interest that are obtained from that exercise are generally surface quantities, such as pressure, heat flux and enthalpy. Then, material response solvers are used to either design the heat shield to an optimal thickness based on a choice of material, or to provide in-depth heating profiles through the material at various select locations, and compare with flight instrumentation such as the ones that flew on NASA’s two most recent Mars missions, MSL and Mars2020. While most of the heating is generally experienced during the continuum part of the entry, the heating within the rarefied regime is significant for some atmospheres, and hence the flow solutions need to be computed using the DSMC method. Ensuring consistency between hypersonic CFD and the DSMC is crucial so that reliable surface quantities can be passed to material response solvers. Studies were performed to compare the two methods at various select locations, for both non-reacting argon flows as well reacting CO2/N2 flows. Preliminary conclusions show that, for non-reacting flows, the agreement between the two methods for surface heating is excellent (within expected uncertainties) for a freestream Knudsen number of 0.0006, and gets progressively worse as the Knudsen number increases to 0.06. Continuum breakdown analyses were performed and showed that, in general, the Gradient Length Local Knudsen number (KnGLL) from Boyd and associated criterion (KnGLL > 0.05) seems conservative in predicting zones of breakdown in the flow, and associated errors for surface quantities. Updated criteria of KnGLL = 2.0 and 0.5 appear to be more appropriate for surface and flow quantities, respectively. Furthermore, when studying reacting flows, our studies showed that while flow quantities are highly dependent on relaxation parameters and chemistry rates, it is possible to obtain a good agreement for surface heating, as long as the continuum breakdown is minimal.

DSMC↗

Recent Updates to the Object Reentry Survival Analysis Tool (ORSAT) Version 7.1

The Object Reentry Survival Analysis Tool (ORSAT) code is maintained and used by the NASA Orbital Debris Program Office (ODPO) and has been under continuous development and improvement since the mid-1990s. ORSAT is an object-oriented reentry simulation tool; it models a satellite as a collection of discrete components that follow independent trajectories upon the breakup of the parent object. Version 7.1 of the tool incorporates five years of new thermal and aerodynamic model development, multi-processor parametric study capability, codebase upgrades, and numerous bug-fixes. The thermal demise model was completely rewritten using a forward-time/central-space numerical stencil and incorporating a new pyrolysis model for fiber-reinforced plastic (FRP) materials. New aerodynamic and aeroheating models for hollow cylinders and hollow square prisms were developed using a combination of flow simulations in the direct simulation Monte Carlo (DSMC) Analysis Code (DAC) and Data Parallel Line Relaxation (DPLR) code and free-flight tests in the University of Texas at San Antonio’s Hypersonic Wind Tunnel. The latest version also incorporates a mechanical, strength-based demise model for FRP materials. Minor improvements include an update to the Fortran 2018 codebase; improved integration and speed with the Python-based, multi-core, parametric study tool, AutoORSAT; and fixes for many minor bugs. This new version of ORSAT will enable more accurate reentry risk assessments for modern satellites. This paper presents an overview of these changes and a summary of the verification and validation performed on the final code.

Benton R. Greene↗

Validating Drag and Heating Coefficients for Hollow Reentry Objects in Continuum Flow Using a Mach 7 Ludwieg Tube

Drag and heating coefficient databases and models are crucial to destructive reentry simulation. The NASA Orbital Debris Program Office (ODPO) develops, maintains, and performs analysis with the Object Reentry Survival Analysis Tool (ORSAT), which comprises drag and heating models for free molecular, transitional, and continuum flow regimes. These models have, in the past, only included solid, convex, blunt shapes (such as boxes, spheres, and cylinders). Previous work led by ODPO includes the extension of these models to hollow cylinders and square boxes in free molecular and transitional flow using the Direct Simulation Monte Carlo (DSMC) method. Since 2019, the ODPO has continued its program of DSMC simulations and extended the project to include analyses with the NASA Data Parallel Line Relaxation (DPLR) program on hollow cylinders and boxes (with varying wall thickness-diameter ratio). In fall 2022, the ODPO began a collaboration with the University of Texas San Antonio (UTSA) to use the Mach 7 Ludwieg Tube facility to validate the model built using numerical simulations. This facility can replicate (at a scale of approximately 100:1) the conditions seen by reentering objects near typical demise altitudes. We present here the drag and heating coefficients derived from the continued DSMC simulations, the new DPLR simulations, and the 26-test series at UTSA.

Chris Ostrom↗

Aerodynamic Implications of Aerocapture Systems for Uranus Orbiters

Exploration of the Ice Giants, Uranus in particular, has been indicated as the highest priority new flagship-class mission by the 2022 Planetary Science Decadal Survey. However, due to it’s location in the solar system, extensive travel time and resources are required for a mission to reach Uranus. Aerocapture offers shorter interplanetary transit times and reduced propellant requirements for such a mission when compared to a traditional propulsive-capture orbiter. Considerations for the aerodynamics of an aerocapture system enabling flagship-class science mission to Uranus are presented. The applicability of a low lift-to-drag entry vehicle aeroshell with flight heritage to a new planet and atmosphere is evaluated. A preliminary aerodatabase is formulated from low-fidelity methods and heritage flight mission data to provide initial estimates of trajectory space to be considered for inserting a spacecraft into orbit at Uranus using aerocapture. Computational fluid dynamics calculations in the free molecular, transitional, and continuum regimes using Direct Simulation Monte Carlo and Navier-Stokes solutions are used to assess the validity of this preliminary aerodatabase. The considered entry vehicle is found to varying levels of agreement with work done by previous flight missions when evaluated for flight in Uranus’ atmosphere. Implications for the aerodynamics of this vehicle as applied in an aerocapture system in flight at Uranus as found by the current work are discussed.

Eli R. Shellabarger↗

Aerodynamic Implications of Aerocapture Systems for Uranus Orbiters

Exploration of the Ice Giants, Uranus in particular, has been indicated as the highest priority new flagship-class mission by the 2022 Planetary Science Decadal Survey. However, due to it's location in the solar system, extensive travel time and resources are required for a mission to reach Uranus. Aerocapture offers shorter interplanetary transit times and reduced propellant requirements for such a mission when compared to a traditional propulsive-capture orbiter. Considerations for the aerodynamics of an aerocapture system enabling flagship-class science mission to Uranus are presented. The applicability of a low lift-to-drag entry vehicle aeroshell with flight heritage to a new planet and atmosphere is evaluated. A preliminary aerodatabase is formulated from low-fidelity methods and heritage flight mission data to provide initial estimates of trajectory space to be considered for inserting a spacecraft into orbit at Uranus using aerocapture. Computational fluid dynamics calculations in the free molecular, transitional, and continuum regimes using Direct Simulation Monte Carlo and Navier-Stokes solutions are used to assess the validity of this preliminary aerodatabase. The considered entry vehicle is found to varying levels of agreement with work done by previous flight missions when evaluated for flight in Uranus' atmosphere. Implications for the aerodynamics of this vehicle as applied in an aerocapture system in flight at Uranus as found by the current work are discussed.

Uranus↗

Simulation of Vacuum Chamber Pressure Distribution with Surrogate Modeling and Uncertainty Quantification

A major challenge in understanding differences in electric propulsion performance in ground tests and in space operations concerns the pressure distribution within the test vacuum chamber. The chamber backpressure is much higher than experienced in space, modifying thruster performance and plume dynamics. Numerical simulation is a key element to determining the background conditions in non-ideal vacuum chamber environments. An important parameter for the accurate simulation of chamber backpressure is the probability that an atom will stick to a cryogenic panel used to pump away the plume gases. This quantity can be used to model vacuum pumps in particle-based kinetic numerical methods. In this work, a three-dimensional direct simulation Monte Carlo code is used to model neutral xenon atoms flowing from the anode of the H9 Hall Effect Thruster within the University of Michigan’s Large Vacuum Test Facility. Simulated pressures are compared with ion gauge pressure measurements to infer the effective sticking coefficient of the chamber’s vacuum pumps. A pressure predicting surrogate model is developed for inference of pump sticking coefficients and for uncertainty quantification. This information enables accurate and useful kinetic simulations of electric propulsion thruster plasma plumes in vacuum chambers.

DSMC↗

Recommended DSMC Collision Model Parameters for Planetary Entry

Hybrid simulation frameworks combining Computational Fluid Dynamics (CFD) and Direct Simulation Monte Carlo (DSMC) are frequently employed to efficiently perform high-fidelity simulations of environments consisting of both continuum and rarified flow. DSMC is a stochastic, particle-based method which solves the fundamental Boltzmann equation and is therefore necessary for high-Knudsen flow where continuum-based assumptions governing CFD break down. However, the DSMC methodology is generally computationally inefficient to model the continuum regime. In a CFD/DSMC hybrid approach, obtaining an accurate, high-fidelity solution hinges on the consistent treatment of transport properties and the thermo-chemical models employed within the two solvers. In principle, in regions where CFD and DSMC are both employed, the same gas mixture under the same conditions should have the same properties, regardless of simulation type. Observed differences should be due to non-equilibrium processes, rather than differences in physical models. The goal of this work is to provide a comprehensive DSMC transport database encompassing the vast majority of known gas species encountered during Earth or other planetary atmospheric entry. This goal is largely possible due to recently performed ab initio quantum chemistry calculations. Combined with other high-fidelity data, the planned database will consist of collision integral data for over 200 neutral and ionized species and over 20000 binary collisions. From these collision integrals, Nelder-Mead optimization is used to compute collision-specific Variable Soft Sphere (VSS) collision model parameters, fitted from 300 K to 20000 K. Initial comparisons of transport properties of relevant equilibrium gas mixtures show great agreement between CFD and DSMC-derived results. The completed database can be readily applied to model binary collisions of any gas mixture containing the included species over the specified temperature range, making it a valuable tool for future planetary probe modeling efforts. An example is shown below in Fig. 1. Equilibrium mixture transport properties for a 35-species mixture composed originally of 10% air and 90% pyrolysis species of a carbon-phenolic ablator material [4] are computed using both fitted VSS Parameters and the original CFD collision integral values. Deviations in computed properties between the two approaches are less than 5% for the entire temperature range.

M. R. Gosma↗

Computational Investigation of Oxidative Etch Pitting in FiberForm and Its Impact on Material Properties

Oxidation-driven carbon erosion does not occur uniformly but rather through the development of localized etch pits at active surface sites. These active sites form due to atomic defects on the carbon surface, making them significantly more reactive than the surrounding, non-defective areas. As a result, these sites are the first to react during ablation, leading to their removal. This process creates new defects in neighboring atoms, increasing their reactivity and causing localized carbon removal around these active sites. In this way, the highly reactive defective areas serve as nucleation points for the formation and growth of etch pits, which can have adverse effects on structural integrity of FiberForm. To better understand how these etch pits impact the material properties of carbon fiber microstructures, we have developed a new capability within the direct simulation Monte Carlo (DSMC) framework to capture the etch pit formation process. This capability, integrated into the DSMC code SPARTA (Stochastic Parallel Rarefied-gas Time-accurate Analyzer), models material removal in the presence of active sites, leading to the formation of etch pits. The current work focuses on studying the effects of these etch pits on the material properties of FiberForm, a widely used base material in thermal protection systems (TPS). The microstructure of virgin FiberForm, obtained via X-ray microtomography, is imported into SPARTA to generate the ablated geometries with etch pits. These modified microstructures are then analyzed using the Porous Microstructure Analysis (PuMA) software to compute various material properties, including elasticity, thermal conductivity, and permeability. We investigate the variation of these properties due to the complex surface topology changes caused by etch pit formation. Additionally, we compare the effects of pitting with the conventional model of shrinking fibers, traditionally used to simulate the ablation of carbon structures. Significant differences emerge between the two approaches. Consequently, this physically realistic model of material removal through etch pit formation offers improved accuracy in predicting the degradation of carbon-based TPS during oxidation. It also provides insights into other mechanisms, such as spallation, where chunks of material are removed into the flow due to etch pit growth. Ultimately, this model enhances our understanding of failure modes in these materials during ablation.

PuMA↗

Aerodynamics of a Uranus Aerocapture System Using a Mars-Heritage Entry Vehicle

Aerodynamic characteristics of an aerocapture system intended to deliver a flagship-class orbiter and probe planetary science mission to Uranus are presented. The aeroshell of the Mars Science Laboratory and Mars 2020 entry vehicles is proposed as a baseline for this system to reduce the amount of necessary technology development. Direct Simulation Monte Carlo and Navier-Stokes computational fluid dynamics solutions are used to characterize the aerodynamic performance of the Mars-heritage vehicle for aerocapture flight at Uranus. These results are incorporated into an aerodatabase for use in six degree-of-freedom trajectory studies and mission design. Updates are made to the Mars-heritage aerodynamic uncertainty model based on observations in the Uranus-specific computational data to ensure the model is conservatively bounding for the proposed flight space. Necessary modifications to the aeroshell for system packaging are found to have minimal effect on aerodynamic performance. The resulting aerodatabase and uncertainty model are used to show the existing Mars-heritage entry vehicles have sufficient aerodynamic performance to achieve required control margin for Uranus aerocapture.

Eli R Shellabarger↗

Aerodynamics of a Uranus Aerocapture System Using a Mars-Heritage Entry Vehicle

Aerodynamic characteristics of an aerocapture system intended to deliver a flagship-class orbiter and probe planetary science mission to Uranus are presented. The aeroshell of the Mars Science Laboratory and Mars 2020 entry vehicles is proposed as a baseline for this system to reduce the amount of necessary technology development. Direct Simulation Monte Carlo and Navier-Stokes computational fluid dynamics solutions are used to characterize the aerodynamic performance of the Mars-heritage vehicle for aerocapture flight at Uranus. These results are incorporated into an aerodatabase for use in six degree-of-freedom trajectory studies and mission design. Updates are made to the Mars-heritage aerodynamic uncertainty model based on observations in the Uranus-specific computational data to ensure the model is conservatively bounding for the proposed flight space. Necessary modifications to the aeroshell for system packaging are found to have minimal effect on aerodynamic performance. The resulting aerodatabase and uncertainty model are used to show the existing Mars-heritage entry vehicles have sufficient aerodynamic performance to achieve required control margin for Uranus aerocapture.

Eli Shellabarger↗

Plume Impingement Software Module for Real-Time Proximity Operations

Successfully executing proximity operations in space, such as docking or in-orbit servicing, requires sophisticated spacecraft design that accounts for induced environments. As a chaser vehicle’s attitude control thrusters fire, they create rarefied plumes that can impact the target vehicle, with the potential to overload components, exceed thermal limits, and spin the target vehicle out of control. High-fidelity simulations of the thruster plume impingement environment require the direct simulation Monte Carlo (DSMC) method, but DSMC is too computationally expensive to simulate proximity operations that involve thousands of thruster firings. For this analysis to be tractable, engineering models of the plume flowfield and impingement events are used to simulate these trajectories [1]. Currently, on-orbit plume impingement environments are modeled through an inefficient open-loop analysis cycle where the vehicle’s flight controller and plume impingement teams iterate on the trajectories until they pass the target vehicle’s plume requirements. As complex on-orbit missions evolve and become more frequent, lengthy design cycles will become operational bottlenecks. To address this gap, this work develops an advanced plume impingement module capable of operating at real-time scale that can be integrated with existing mission planning tools and onboard flight systems. The plume module leverages state-of-the-art plume simulation techniques [2] to deliver fast, physics-based impingement predictions in a software architecture that can be tailored to diverse proximity operations scenarios. A prototype of this plume impingement module is built to demonstrate the feasibility of real-time performance. This prototype completes plume impingement calculations in microseconds per target geometry mesh point. The software serves as a foundational capability for plume-aware trajectory design, operational risk assessment, and future autonomous decision-making systems.

Plume Impingement↗

Preliminary results of a Monte Carlo simulation of burst directions by BATSE

The effect of varying BATSE trigger parameters on the modeled BATSE detection rate is investigated numerically. Quantitative estimates are obtained of the systematic effects generated by the complex interplay of trigger times, variations in the signal-to-noise ratio for burst detection as well as the time scale over which backgrounds are determined, and the number of required detections above threshold. It is found, in particular that employing a third detection, at a reduced signal-to-noise ratio, to resolve a burst does not increase the detection rate. It is also shown that the BATSE detection rate is insensitive to variations in the time scale over which the background is determined.

Higdon, J. C.↗

On recontamination and directional-bias problems in Monte Carlo simulation of PDF turbulence models

Turbulent combustion can not be simulated adequately by conventional moment closure turbulence models. The difficulty lies in the fact that the reaction rate is in general an exponential function of the temperature, and the higher order correlations in the conventional moment closure models of the chemical source term can not be neglected, making the applications of such models impractical. The probability density function (pdf) method offers an attractive alternative: in a pdf model, the chemical source terms are closed and do not require additional models. A grid dependent Monte Carlo scheme was studied, since it is a logical alternative, wherein the number of computer operations increases only linearly with the increase of number of independent variables, as compared to the exponential increase in a conventional finite difference scheme. A new algorithm was devised that satisfies a restriction in the case of pure diffusion or uniform flow problems. Although for nonuniform flows absolute conservation seems impossible, the present scheme has reduced the error considerably.

Hsu, Andrew T.↗

On recontamination and directional-bias problems in Monte Carlo simulation of PDF turbulence models

Turbulent combustion can not be simulated adequately by conventional moment closure turbulent models. The probability density function (PDF) method offers an attractive alternative: in a PDF model, the chemical source terms are closed and do not require additional models. Because the number of computational operations grows only linearly in the Monte Carlo scheme, it is chosen over finite differencing schemes. A grid dependent Monte Carlo scheme following J.Y. Chen and W. Kollmann has been studied in the present work. It was found that in order to conserve the mass fractions absolutely, one needs to add further restrictions to the scheme, namely alpha(sub j) + gamma(sub j) = alpha(sub j - 1) + gamma(sub j + 1). A new algorithm was devised that satisfied this restriction in the case of pure diffusion or uniform flow problems. Using examples, it is shown that absolute conservation can be achieved. Although for non-uniform flows absolute conservation seems impossible, the present scheme has reduced the error considerably.

Hsu, Andrew T.↗