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At least 361 records · Page 20

Reusable Metallic Thermal Protection Systems Development

Metallic thermal protection systems (TPS) are being developed to help meet the ambitious goals of future reusable launch vehicles. Recent metallic TPS development efforts at NASA Langley Research Center are described. Foil-gage metallic honeycomb coupons, representative of the outer surface of metallic TPS were subjected to low speed impact, hypervelocity impact, rain erosion, and subsequent arcjet exposure. TPS panels were subjected to thermal vacuum, acoustic, and hot gas flow testing. Results of the coupon and panel tests are presented. Experimental and analytical tools are being developed to characterize and improve internal insulations. Masses of metallic TPS and advanced ceramic tile and blanket TPS concepts are compared for a wide range of parameters.

Blosser, Max L.↗

Nanostructured Thermal Protection Systems for Space Exploration Missions

Strong research and development programs in nanotechnology and Thermal Protection Systems (TPS) exist at NASA Ames. Conceptual studies have been undertaken to determine if new, nanostructured materials (composites of existing TPS materials and nanostructured composite fibers) could improve the performance of TPS. To this end, we have studied various candidate heatshields, some composed of existing TPS materials (with known material properties), to provide a baseline for comparison with others that are admixtures of such materials and a nanostructured material. In the latter case, some assumptions were made about the thermal conductivity and strength of the admixture, relative to the baseline TPS material. For the purposes of this study, we have made the conservative assumption that only a small fraction of the remarkable properties of carbon nanotubes (for example) will be realized in the material properties of the admixtures employing them. The heatshields studied included those for Sharp leading edges (appropriate to out-of-orbit entry and aero-maneuvering), probes, an out-of-orbit Apollo Command Module (as a surrogate for NASA's new Crew Exploration Vehicle [CEV]), a Mars Sample Return Vehicle and a large heat shield for Mars aerocapture missions. We report on these conceptual studies, which show that in some cases (not all), significant improvements in the TPS can be achieved through the use of nanostructured materials.

Arnold, J. O.↗

Overview of the Orion Thermal Protection System

The Orion spacecraft is being developed as part of the Constellation Exploration Program and will serve as the United States crewed transportation system to the International Space Station after the retirement of the Space Shuttle in 2010 and as the eventual means to return U.S. astronauts to the Moon. Therefore, Orion is being designed for reentry missions from both low Earth orbit and from Lunar-return trajectories. This presentation will provide an overview of the development of the Orion TPS, a critical component in the development of the spacecraft. The thermal protection system (TPS) that protects the crew module from the extreme environments associated with Earth atmospheric reentry consists of a forward heatshield and an aft backshell. The requirements that drive the design of the TPS will be discussed, including several key requirements that establish a precedent for U.S. human-rated spacecraft. For the first time in U.S. human spaceflight, a vehicle s TPS is being designed with a specific, derived requirement for reliability. Also, due to the increased presence of spacecraft in Earth s orbit in recent decades, requirements for micro-meteoroid/orbital debris damage tolerance are also a driving requirement that has affected the selection of portions of the TPS. The efforts to select materials and to define a preliminary design for both the heatshield and the backshell will be described. This will include a discussion of the design challenges presented by the numerous penetrations on both the backshell and the heatshield. Finally, the verification and validation plan which is currently under development to certify the TPS for human-rated missions will be outlined. To support the execution of this plan, a ground test campaign for both thermal and structural performance is being designed. This test campaign will directly support thermal and thermal/structural analyses that also are fundamental to the certification effort.

Kowal, T. John↗

Mars 2020 Entry, Descent and Landing Instrumentation (MEDLI2)

This paper will introduce Mars Entry Descent and Landing Instrumentation (MEDLI2) on NASA's Mars2020 mission. Mars2020 is a flagship NASA mission with science and technology objectives to help answer questions about possibility of life on Mars as well as to demonstrate technologies for future human expedition. Mars2020 is scheduled for launch in 2020. MEDLI2 is a suite of instruments embedded in the heatshield and backshell thermal protection systems of Mars2020 entry vehicle. The objectives of MEDLI2 are to gather critical aerodynamics, aerothermodynamics and TPS performance data during EDL phase of the mission. MEDLI2 builds up the success of MEDLI flight instrumentation on Mars Science Laboratory mission in 2012. MEDLI instrumentation suite measured surface pressure and TPS temperature on the heatshield during MSL entry into Mars. MEDLI data has since been used for unprecedented reconstruction of aerodynamic drag, vehicle attitude, in-situ atmospheric density, aerothermal heating, transition to turbulence, in-depth TPS performance and TPS ablation. [1,2] In addition to validating predictive models, MEDLI data has highlighted extra margin available in the MSL forebody TPS, which can potentially be used to reduce vehicle parasitic mass. MEDLI2 expands the scope of instrumentation by focusing on quantities of interest not addressed in MEDLI suite. The type the sensors are expanded and their layout on the TPS modified to meet these new objectives. The paper will provide key motivation and governing requirements that drive the choice and the implementation of the new sensor suite. The implementation considerations of sensor selection, qualification, and demonstration of minimal risk to the host mission will be described. The additional challenges associated with mechanical accommodation, electrical impact, data storage and retrieval for MEDLI2 system, which extends sensors to backshell will also be described.

Thermal Protection System↗

MELDI2 Do No Harm Test Series

Mars 2020 will fly the Mars Entry, Descent, and Landing Instrumentation II (MEDLI2) sensor suite consisting of a total of seventeen instrumented thermal sensor plugs, eight pressure transducers, two heat flux sensors, and one radiometer embedded in the thermal protection system (TPS). Of the MEDLI2 instrumentation, eleven instrumented thermal plugs and seven pressure transducers will be installed on the heatshield of the Mars 2020 vehicle while the rest will be installed on the backshell. The goal of the MEDLI2 instrumentation is to directly inform the large performance uncertainties that contribute to the design and validation of a Mars entry system. A better understanding of the entry environment and TPS performance could lead to reduced design margins enabling a greater payload mass-fraction and smaller landing ellipses. To prove that the MEDLI2 system will not degrade the performance of the Mars 2020 TPS, an Aerothermal Do No Harm (DNH) test series was designed and conducted. Like Mars 2020's predecessor, Mars Science Laboratory (MSL), the heatshield material will be Phenolic Impregnated Carbon Ablator (PICA); the Mars 2020 entry conditions are enveloped by the MSL design environments, therefore the development and qualification testing performed during MEDLI is sufficient to show that the similar MEDLI2 heatshield instrumentation will not degrade PICA performance. However, given that MEDLI did not include any backshell instrumentation, the MEDLI2 team was required to design and execute a DNH test series utilizing the backshell TPS material (SLA-561V) with the intended flight sensor suite. To meet the requirements handed down from Mars 2020, the MEDLI2 DNH test series emphasized the interaction between the MEDLI2 sensors and sensing locations with the surrounding backshell TPS and substrucutre. These interactions were characterized by performing environmental testing of four 12" by 12" test panels, which mimicked the construction of the backshell TPS and the integration of the MEDLI2 sensors as seen in Figure 1. The testing included thermal vacuum/ cycling, random vibration, shock, and arc jet testing. The test panels were fabricated by Lockheed Martin, establishing techniques that will be utilized during the Mars 2020 vehicle installation. Each test panel included one thermal sensor plug (two embedded thermocouples), one heat flux sensor, and multiple pressure port holes for evaluation. This presentation will discuss the planning and execution of the MEDLI2 DNH test series. Selected highlights and results of each environmental test will be presented, and lessons learned will be addressed that will feed forward into the planning for the MEDLI2 flight system certification testing.

Heatshield↗

Mars2020 Entry, Descent, and Landing Instrumentation 2 (MEDLI2) Do No Harm Test Series

A total of seventeen instrumented thermal sensor plugs, eight pressure transducers, two heat flux sensors, and one radiometer are planned to be utilized on the Mars 2020 missions thermal protection system (TPS) as part of the Mars Entry, Descent, and Landing Instrumentation II (MEDLI2) project. Of the MEDLI2 instrumentation, eleven instrumented thermal plugs and seven pressure transducers will be installed on the heatshield of the Mars 2020 vehicle while the rest will be installed on the backshell. The goal of the MEDLI2 instrumentation is to directly inform the large performance uncertainties that contribute to the design and validation of a Mars entry system. A better understanding of the entry environment and TPS performance could lead to reduced design margins enabling a greater payload mass-fraction and smaller landing ellipses. To prove that the MEDLI2 system will not degrade the performance of the Mars 2020 TPS, an Aerothermal Do No Harm (DNH) test series was designed and conducted. Like Mars 2020s predecessor, Mars Science Laboratory (MSL), the heatshield material will be Phenolic Impregnated Carbon Ablator (PICA); the Mars 2020 entry conditions are enveloped by the MSL design environments, therefore the development and qualification testing performed during MEDLI is sufficient to show that the similar MEDLI2 heatshield instrumentation will not degrade PICA performance. However, given that MEDLI did not include any backshell instrumentation, the MEDLI2 team was required to design and execute a DNH test series utilizing the backshell TPS material (SLA-561V) with the intended flight sensor suite. To meet the requirements handed down from Mars 2020, the MEDLI2 DNH test series emphasized the interaction between the MEDLI2 sensors and sensing locations with the surrounding backshell TPS and substrucutre. These interactions were characterized by performing environmental testing of four 12 by 12 test panels, which mimicked the construction of the backshell TPS and the integration of the MEDLI2 sensors as seen in Figure 1. The testing included thermal vacuumcycling, random vibration, shock, and arc jet testing. The test panels were fabricated by Lockheed Martin, establishing techniques that will be utilized during the Mars 2020 vehicle installation. Each test panel included one thermal sensor plug (two embedded thermocouples), one heat flux sensor, and multiple pressure port holes for evaluation.This presentation will discuss the planning and execution of the MEDLI2 DNH test series. Selected highlights and results of each environmental test will be presented, and lessons learned will be addressed that will feed forward into the planning for the MEDLI2 flight system certification testing.

backshell↗

Challenges and Opportunities for Ensuring Entry System Technology Readiness for Ice Giants Probe Missions

The Ice Giants represent a distinct class of planets within our solar system, and appear to be similar to most exoplanets that have been detected thus far. Exploring Ice Giants in our Solar System would allow us to better understand their formation and evolution processes, and thus help establish scientific links to exoplanets. In situ exploration using probes similar to Galileo, along with an orbiter or a relay spacecraft, will require entry followed by deployment of the descent probe containing science instruments into Uranus or Neptune atmosphere. The challenge is not in the deployment of the probe, but in the atmospheric entry prior to deployment. The entry system has to have a capable, robust and efficient ablative thermal protection system (TPS) designed to protect the descent probe from the thermal and mechanical entry loads. Although entries into Ice Giants may not be as demanding as the Galileo entry at Jupiter, the entry environments will be more severe than environments for Mars, Sample Return missions, and Venus, and will therefore require robust TPS. While Galileo Probe’s success, nearly 25 years ago, should give us confidence, the recession data from the Galileo entry informs us that the entry environment was under-predicted and the design thickness was barely adequate. The lesson learned from the Galileo probe for future Ice Giant missions will require us to be cautious and demand a more robust design. The TPS technology used on the Galileo entry system no longer exists due to atrophy of manufacturing processes. Instead of attempting to revive Galileo-legacy TPS technology, NASA invested in a new and innovative TPS called HEEET (Heat-shield for Extreme Entry Environment Technology). HEEET has been matured, and is now ready to support future missions not only to the Ice Giants but also for Venus, high-speed sample return, and Saturn probe missions. This lead talk, intended for the technology section of the workshop, will cover entry, descent, and deployment (EDD), with an emphasis on entry. A brief history of the TPS challenges for extreme entry missions will be given, along with a quick overview of the concept of operations for EDD. The development and maturation of HEEET system capability will be described. Data gathered in ground-test facilities in the US will be highlighted to show that the technology is mature and ready for Ice Giant missions. All thermal protection systems carry some risk as a result of ground test limitations and Ice Giant missions present some unique challenges. These challenges are not only technical, but also due to limitations in the currently established manufacturing and integration. In addition, the concerns that arise due to the potential for atrophy for future Ice Giant missions a decade or more from now will be analyzed. Plausible avenues for mitigation will be presented. There are two planned companion presentations by Dr. Prabhu and Dr. Hwang that will dive deeper into the challenges and opportunities. This intended talk will set the stage for their presentations.

Venkatapathy, Ethiraj↗

Challenges and Opportunities For Ensuring Entry System Technology Readiness For Ice Giants Probe Missions

The Ice Giants represent a distinct class of planets within our solar system, and appear to be similar to most exoplanets that have been detected thus far. Exploring Ice Giants in our Solar System would allow us to better understand their formation and evolution processes, and thus help establish scientific links to exoplanets. In situ exploration using probes similar to Galileo, along with an orbiter or a relay spacecraft, will require entry followed by deployment of the descent probe containing science instruments into Uranus or Neptune atmosphere. The challenge is not in the deployment of the probe, but in the atmospheric entry prior to deployment. The entry system has to have a capable, robust and efficient ablative thermal protection system (TPS) designed to protect the descent probe from the thermal and mechanical entry loads. Although entries into Ice Giants may not be as demanding as the Galileo entry at Jupiter, the entry environments will be more severe than environments for Mars, Sample Return missions, and Venus, and will therefore require robust TPS. While Galileo Probe’s success, nearly 25 years ago, should give us confidence, the recession data from the Galileo entry informs us that the entry environment was under predicted and the design thickness was barely adequate. The lesson learned from Galileo probe for future Ice Giant missions will require us to be cautious and demand a more robust design. The TPS technology used on Galileo entry system no longer exists due to atrophy of manufacturing processes. Instead of attempting to revive Galileo-legacy TPS technology, NASA invested in a new and innovative TPS called HEEET (Heat-shield for Extreme Entry Environment Technology). HEEET has been matured, and is now ready to support future missions not only to the Ice Giants but also for Venus, high-speed sample return, and Saturn probe missions. This lead talk, intended for the technology section of the workshop, will cover entry, descent, and deployment (EDD), with an emphasis on entry. A brief history of the TPS challenges for extreme entry missions will be given along with a quick overview of the concept of operations for EDD. The development and maturation of HEEET system capability will be described. Data gathered in ground-test facilities in the US will be highlighted to show that the technology is mature and ready for Ice Giant missions. All thermal protection systems carry some risk as a result of ground test limitations and Ice Giant missions present some unique challenges. These challenges are not only technical, but also due to limitations in the currently established manufacturing and integration. In addition, the concerns that arise due to potential for atrophy for future Ice Giant mission a decade or more from now will be analyzed. Plausible avenues for mitigation will be presented. There are two companion planned presentations by Dr. Prabhu and Dr. Hwang will dive deeper in the challenges and opportunities. This intended talk will set the stage for their presentations.

Venkatapathy, Ethiraj↗

Ablators - From Apollo to Future Missions to Moon, Mars and Beyond

Apollo was designed to carry astronauts safely back from the Moon at return speeds exceeding 11 km/s and requireddevelopment of a new ablative thermal protection system (TPS) to protect the capsule from entry heating. Mercuryand Gemini, that preceded Apollo, were focused on Earth orbiting system demonstration and lessons learned fromthem were used in Apollo. The ablative material and associated system development for Lunar return conditionsrequired considerable ground and flight testing. Mars Viking Lander missions required a new lighter weight ablatoras entry heating was benign compared to Apollo. Pioneer-Venus and Galileo Probe missions required a new and morecapable ablator than Apollo. After two decades, Mars Pathfinder followed by Mars Exploration Rover missions,smaller than Viking but more demanding, were able to use Viking ablative TPS. At the same time, advances in manufacturing and materials technology led to development of innovative lightweight ablators. These new ablators enabled Stardust and Genesis Sample Return Missions. Around the turn of this century, NASA decided on a scaled-upversion of the Apollo capsule for human exploration of Moon and Mars and the ablative heat shield to protect the CrewExploration Vehicle ended up being the Apollo ablative TPS. The Artemis 1 mission is currently fitted with tiledsystem, different than Orion EFT-1 but with the Apollo ablative material as a result of lessons learned. NASA iscurrently planning on sample return missions from Mars, and this will require robust ablative TPS that can providehigher reliability than any other past mission. There are still unexplored high scientific value destinations in the solarsystem. In situ exploration of Uranus, Neptune, Saturn and sample return missions with return speed much higher thanStardust will require ablators capable of withstanding extreme entry that are also efficient. New ablative TPS havebeen developed in anticipation of these future missions. This paper is intended to tell the story of these ablators,illustrated through examples. We see the use of flight proven ablators was sometimes a risky proposition and newablators perceived to be higher risk have proved otherwise. The history of ablators illustrates the challenges eachmission had to address, either through the use of flight proven or new ablative TPS, to be successful.

Venkatapathy, Ethiraj↗

Thermal Protection System Materials for Sample Return Missions

This white paper from the Thermal Protection System (TPS) community to the NRC Decadal Survey Sub-Panels provides an overview of TPS materials needed for future Sample Return (SR) missions. We consider the capability of heritage TPS material used by recent SR missions and identify appropriate materials for future SR missions. A prime conclusion is that the current TPS materials, if properly maintained, offer good low-density solutions for lower velocity (<13.5 km/s) sample return missions without planetary protection back-protection concerns. Furthermore, missions that have a larger capsule, a higher entry speed (>13.5 km/s), or back-protection concerns will leverage recently developed mid-density TPS materials. To maintain NASA’s Sample Return capabilities in the coming decade, we recommend that NASA continue to invest in sustainment of relevant TPS materials, as well as ground-test facilities, predictive entry modeling, and flight instrumentation.

mission design↗

Case Study of Meteoroid Fluence on a Mars Sample Return Mission

The Mars Sample Return Campaign must satisfy a Back Planetary Protection requirement that limits the risk of biological contamination of the Earth by Martian microbes. The Earth Re-turn Orbiter (ERO), being developed by the European Space Agency (ESA), will carry a Capture, Containment and Return System (CCRS), which is being developed by NASA to retrieve orbiting samples (OS) from Mars orbit, surround them with two containment layers to create a Contained OS (COS), and transfer the COS to the Earth Entry System (EES), which will be re-leased by ERO to carry the samples through entry, descent and landing at the Utah Test and Training Range. Micrometeoroid impact damage to the Thermal Protection System (TPS) of the EES, which may occur at any time in the ERO mission, is recognized as a potential risk driver for loss of sample containment that needs to be rigorously assessed. A Micrometeoroid Protection System (MMPS) will be implemented to limit that risk. The MMPS consists of a shield covering the TPS called the Micrometeoroid Garage (MMG) and a system of cameras to inspect the TPS. An extensive study was performed by the CCRS Project in collaboration with the NASA Engineering and Safety Center (NESC)to assess the probability of damage to the MMG and TPS by meteoroids over the entire ERO mission. This included the computation of the meteoroid fluence on the MMG and directly on the TPS after EES separation, and assessment of damage to the MMG and TPS via hypervelocity impact tests, hydrocode simulations, and empirical damage prediction and ballistic limit equations (BLEs). The focus of this paper is the meteoroid fluence on the MMG.

Micrometeoroid↗

Case Study of Meteoroid Fluence on a Mars Sample Return Mission

The Mars Sample Return Campaign must satisfy a Back Planetary Protection requirement that limits the risk of biological contamination of the Earth by Martian microbes. The Earth Re-turn Orbiter (ERO), being developed by the European Space Agency (ESA), will carry a Capture, Containment and Return System (CCRS), which is being developed by NASA to retrieve orbiting samples (OS) from Mars orbit, surround them with two containment layers to create a Contained OS (COS), and transfer the COS to the Earth Entry System (EES), which will be re-leased by ERO to carry the samples through entry, descent and landing at the Utah Test and Training Range. Micrometeoroid impact damage to the Thermal Protection System (TPS) of the EES, which may occur at any time in the ERO mission, is recognized as a potential risk driver for loss of sample containment that needs to be rigorously assessed. A Micrometeoroid Protection System (MMPS) will be implemented to limit that risk. The MMPS consists of a shield covering the TPS called the Micrometeoroid Garage (MMG) and a system of cameras to inspect the TPS. An extensive study was performed by the CCRS Project in collaboration with the NASA Engineering and Safety Center (NESC)to assess the probability of damage to the MMG and TPS by meteoroids over the entire ERO mission. This included the computation of the meteoroid fluence on the MMG and directly on the TPS after EES separation, and assessment of damage to the MMG and TPS via hypervelocity impact tests, hydrocode simulations, and empirical damage prediction and ballistic limit equations (BLEs). The focus of this paper is the meteoroid fluence on the MMG.

micrometeoroid↗

Boundary-Layer Flow Simulations Over Ablating Woven Thermal Protection System Material

Spallation is the mechanical removal of small chunks of material gets removed typically due to high shear conditions of the flow field. This reduces the ability of the thermal protection system (TPS) material to protect the spacecraft as well as cause turbulence in the flow causing higher heating rates. In this work, we focus on the material removal through ablation and high shear flow within the boundary layer region of woven TPS material. Woven TPS (WTPS) material is the latest class of material developed by NASA, to be used within the next generation of space flights. They are complex interlocked weaves designed to create a rigid structure that is highly resistant to heat and can be easily designed and tailored for a wide variety of entry environments. Due to material removal resulting from chemical degradation, the structural integrity of TPS material is affected. Spallation occurs when this structurally compromised material is exposed to the high shear flow conditions within the boundary layer. In order to understand the spallation mechanism within WTPS material, we first perform the material removal simulations which occur primarily through oxidation to obtain the microstructure at various stages of degradation. These simulations are performed using the Porous Microstructure Analysis (PuMA) software developed at NASA Ames. The micro-structure geometry used within these simulations were generated artificially to be similar to the 3D weave architecture of MSR-EEV (Mars Sample Return - Earth Entry Vehicle). The various eroded TPS micro-structures are then subjected to the boundary layer flow conditions to obtain critical surface quantities which contribute to the structural failure mechanism such as heat flux, pressure, and shear stress. The direct simulation Monte Carlo (DSMC) methodology is used to perform these simulations in order to accurately capture the strong gradients within the high-temperature boundary layer flow over the intricate geometry of WTPS material. The boundary layer profile is directly taken from the Computational Fluid Dynamics (CFD) simulation and provided as boundary conditions to the DSMC inlet and outlet. Further, the variation of these properties as the microstructure undergoes changes due to oxidation is also investigated. Finally, these quantities are used as input in PuMA to understand the material expansion/compression and strain within the woven TPS geometry and help in developing a comprehensive spallation and structure failure model.

microstructure↗

A Multi-Probe Mission at Jupiter is Within our Reach!!

Soon after Galileo Probe mission, capabilities to manufacture and test heritage carbon-phenolic (HCP) TPS atrophied. The impact of capability loss to Outer Planet probe missions, Venus in-situ and Mars Sample Return (MSR) missions was realized after two decades. MSR (1997 – 2006) initiated a search and recover of HCP. Decadal Survey (2003) recommended JPOP mission (Jupiter Polar Orbiter and Probe), but lack of HCP TPS resulted in Juno being proposed without a probe. Decadal Survey (2013) recognized and advised NASA to close the TPS gap. With the community support, NASA initiated a technology development effort to close this gap in 2019 and today, missions to Venus, Saturn, Uranus, and MSR are enabled by new 3-D Woven TPS. Jupiter, the most demanding mission from an entry and TPS perspective ever, still lacks a viable qualified TPS. While the Science community needs to make the case for going back to Jupiter with a Probe, this work is an assessment of emerging capabilities to support such a mission when needed. Recent SOA developments are very promising to close this technology gaps. Encourage the Science Community about the feasibility of future Jupiter Multi-Probes Mission Engage the Entry System/TPS Technology Community as to the emerging capabilities and need to preserve them Educate and excite the early career and next generation students interested in future Science and technology challenge.

Ethiraj Venkatapathy↗

Boundary-Layer Flow Simulations Over Ablating Woven Thermal Protection System Material

Spallation is the mechanical removal of small chunks of material gets removed typically due to high shear conditions of the flow field. This reduces the ability of the thermal protection system (TPS) material to protect the spacecraft as well as cause turbulence in the flow causing higher heating rates. In this work, we focus on the material removal through ablation and high shear flow within the boundary layer region of woven TPS material. Woven TPS (WTPS) material is the latest class of material developed by NASA, to be used within the next generation of space flights. They are complex interlocked weaves designed to create a rigid structure that is highly resistant to heat and can be easily designed and tailored for a wide variety of entry environments. Due to material removal resulting from chemical degradation, the structural integrity of TPS material is affected. Spallation occurs when this structurally compromised material is exposed to the high shear flow conditions within the boundary layer. In order to understand the spallation mechanism within WTPS material, we first perform the material removal simulations which occur primarily through oxidation to obtain the microstructure at various stages of degradation. These simulations are performed using the Porous Microstructure Analysis (PuMA) software developed at NASA Ames. The micro-structure geometry used within these simulations were generated artificially to be similar to the 3D weave architecture of MSR-EEV (Mars Sample Return - Earth Entry Vehicle). The various eroded TPS micro-structures are then subjected to the boundary layer flow conditions to obtain critical surface quantities which contribute to the structural failure mechanism such as heat flux, pressure, and shear stress. The direct simulation Monte Carlo (DSMC) methodology is used to perform these simulations in order to accurately capture the strong gradients within the high-temperature boundary layer flow over the intricate geometry of WTPS material. The boundary layer profile is directly taken from the Computational Fluid Dynamics (CFD) simulation and provided as boundary conditions to the DSMC inlet and outlet. Further, the variation of these properties as the microstructure undergoes changes due to oxidation is also investigated. Finally, these quantities are used as input in PuMA to understand the material expansion/compression and strain within the woven TPS geometry and help in developing a comprehensive spallation and structure failure model.

microstructure↗

Analysis of Launch Vehicle Liftoff Debris: Historical Perspective from Space Shuttle and Application to Artemis I

Human exploration-class launch vehicles are inherently prone to debris due to the extreme environments generated during pre-launch operations, liftoff, and flight. The use of cryogenic propellants often requires thermal protection system (TPS) coatings, typically foam, to maintain the propellant conditions in the tank and prevent an accumulation ice on the external surface of the vehicle. Some ice growth is to be expected at umbilical interfaces, vents, flanges, or brackets where it is difficult to apply TPS. This ice may come loose at any time due to wind on the launch pad, structural vibration and acoustics after rocket ignition, or aerodynamic forces during flight. This phenomena is especially apparent on vehicles with no TPS, such as the Saturn V rockets used in the Apollo Program, see Figure 1. During propellant tanking, the thermal contraction of the underlying substrate may generate cracks in the TPS (Figure 1). Chunks of TPS can release due to the expansion of ingested gas from cryopumping or from aerodynamic forces if the crack creates an offset surface. Most foams will also have a certain amount of “popcorning” where small pieces of foam will pop off during flight because of the differential between the static surface pressure and the pressure of the gas trapped in the foam cell structure. There are a number of other coating or closeout materials that may be shed from the vehicle and become debris. During pre-launch operations and liftoff, the vehicle may also be exposed to debris originating from the launch pad or ground support equipment. This debris is separate from foreign object debris, or FOD, which is not intended to be present and is strictly controlled through operations and maintenance procedures. In this case, debris is generated from hardware and materials that are necessary for launch and are subject to the intense vibration, acoustics, and direct plume impingement of the launch environment. Examples include ice from umbilicals, tape and tie wraps that protect cables, and rust or corrosion from the launch platform. While NASA has historically been aware of debris as a potential issue that could cause a failure resulting in loss of mission, loss of vehicle, or loss of crew, the likelihood and severity of that risk was not always well understood or given sufficient weight in program and flight decisions. After the Space Shuttle Columbia accident (STS-107), the investigation found that foam TPS debris shed from the external tank was the proximate cause of the damage to the orbiter wing. Six previous observations of debris released from the foam ramp that covered the bipod connecting the forward end of the orbiter to the external tank resulted in minor changes or were determined to be accepted flight risks. Two occurrences of bipod ramp foam loss were not identified until the STS-107 investigation. Despite the damage inflicted by these debris strikes, the Shuttle Program Requirements Control Board deemed the vehicle safe to fly. During the Return to Flight effort following the Columbia disaster, NASA Engineering developed a process for the assessment of debris transport, impact, and damage tolerance to support independent assessments of risk by NASA Safety and Mission Assurance (S&MA). Under this system, each element (vehicle or ground system) defines a catalog of all expected debris based on launch history, component testing, or analysis. Debris transport analysis (DTA) is conducted using the debris catalog characteristics and potential flow transport mechanisms (e.g., vehicle aerodynamics, gravity, wind, plume-driven). The predicted debris impact locations and velocities are provided to the hardware owners, who use available test data and analysis to determine whether each component can withstand the impacts. In cases where the element hardware may be severely damaged or fail, the options are to mitigate the debris source through some change in design or operation, or to work with S&MA to try to characterize the probability of the impact and damage for program risk acceptance. Because of the differences in debris characteristics and transport, the DTA has been divided between the Liftoff and Ascent regimes. The development and application of Liftoff DTA methodology from the Shuttle Program to the current Artemis Program is the subject of this paper. Liftoff DTA covers the time from the start of pre-launch operations at the launch pad, up until the vehicle clears the launch tower and there is no longer any interaction with ground systems. Debris transport during this period is broadly classified as either gravity, wind, and plume-entrained (GWPE) or plume driven (PD). GWPE debris is generally lower speed, travelling in a forward-to-aft direction. PD transport includes flow features from the rocket ignition transient, as well as plume impingement and recirculation that occur as the vehicle lifts off the launch platform. In these cases, the debris typically moves in an aft-to-forward direction at higher speeds. The applicable transport mechanisms must be considered for each piece of debris depending on the material, and release location and time. For example, rust or metallic debris from the tower could fall (GWPE) and impact the vehicle before landing on the launch platform deck where it could be also be transported by plume impingement (PD). However, falling ice (GWPE) from an umbilical is unlikely to survive impact with the vehicle or launch platform and be available for PD transport. Modeling of debris transport is accomplished using a set of DTA tools which simulate debris trajectories subject to a reference frame acceleration (i.e., gravity) and aerodynamic drag. Where the trajectory encounters a solid surface, the debris is allowed to rebound with a specified coefficient of restitution. The drag is calculated by interpolating the fluid state at each point in the debris trajectory from high-fidelity computational fluid dynamics (CFD) simulations of the launch vehicle and pad. The CFD data may either be static (steady state or time averaged), typically for GWPE transport, or dynamic (time-accurate) for PD flow features like the ignition transient. Examples of the CFD flow field solutions for the Space Launch System (SLS) rocket and launch pad are shown in Figure 2. Typical SLS debris trajectory predictions from DTA are illustrated in Figure 3. The final version of this paper will include a more detailed examination of the Liftoff DTA process developed during the Shuttle Program, and how it has been augmented and applied to the SLS rocket under the Artemis Program. Comparisons with debris observations from the Artemis I launch will demonstrate validation of the tools and methodology.

Debris↗

Bringing the Heat: Thermal Protection Systems for Low Earth Orbit Transportation and Lunar Exploration

Thermal protection systems (TPS) protect spacecraft from the heating associated with hypersonic flight through a planet’s atmosphere. The materials are subjected to extreme heating and the overall system must be engineered to reliably protect the spacecraft structure during atmospheric entry. The talk will introduce TPS and describe three NASA-led efforts to develop TPS materials and manufacturing processes. The first effort studied thermally stable ceramic aerogels for use in thermal barriers and high temperature seals. A design framework for such materials is proposed, linking the thermal stability performance data with existing material property measurements. The second project, Additive Manufacturing of Thermal Protection Systems (AMTPS), developed an automated, additive approach for ablative heat shield manufacturing. Novel material systems and manufacturing methods were developed to reduce the time required to manufacture ablative TPS heat shields. The third effort tackles a critical challenge of material obsolescence for silica fiber based reusable TPS. The properties and performance of heritage silica fiber are quantified and compared to modern alternatives to support qualification for flight. The talk will also describe other work in TPS conducted by the Thermal Design Branch at NASA JSC and opportunities for students and faculty to get involved with NASA.

Nathaniel Olson↗

Improvements to Thermal Protection System Design of Aerocapture Systems for Uranus Orbiters

The National Academies Planetary Science and Astrobiology Decadal Survey identified Uranus and Neptune - called Ice Giants - as the priority destinations for science. The survey assessed both a mission to Uranus through the Uranus Orbiter and Probe (UOP) concept, and Neptune through the Neptune-Triton Odyssey concept and determined that Uranus is the highest priority for a Flagship class mission. The UOP mission concept planned to deliver an in situ probe and conduct a multi-year orbital tour of the system to meet the science objectives. While the Uranus mission is currently viable with launch windows starting in 2031 using existing launch vehicles, the mission has a cruise phase of at least 12 years and would require more than half of its weight in fuel propellant to achieve the change in velocity necessary for orbital insertion. Aerocapture uses aerodynamic forces generated on a vehicle by the planet's atmosphere to modulate a spacecraft's trajectory, decreasing spacecraft velocity, and allowing mission designers to target the final orbital state. Aerocapture reduces the time-of-flight from Earth to Uranus over a fully propulsive solution, opening up more launch opportunities to arrive in the 2040's to the mission's science objectives. Aerocapture also allows a payload mass increase by mitigating the need for fuel to retropropulsively insert the payload into orbit, thereby increase the science that can be performed. For an aerocapture mission structure using a traditional aeroshell to deliver the UOP scientific payload to Uranus, Conformal Phenolic Impregnated Carbon Ablator (C-PICA) was determined to be the best-performing forebody thermal protection system (TPS) and other candidate aftbody TPS options were presented as feasible. This paper focuses on A) evaluating C-PICA as a forebody TPS using stressing entry conditions associated with a large range of potential Uranus flagship launch vehicles and interplanetary trajectories, B) widening the aftbody TPS candidates for new mass-efficient and cost-efficient solutions, and C) a summary list of actions remaining to provide a technically feasible and supply-robust set of TPS for an aerocapture vehicle to the Ice Giants is presented.

C-PICA↗