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NASA NTRSDate not supplied

BEAST: Expanding Sustainable Data Infrastructure for High-Enthalpy Facilities

Reproducible, data-driven thermal protection system (TPS) research requires that experimental records from high-enthalpy testing be consistently structured, traceable, and accessible across campaigns and institutions. In practice, however, arcjet and plasma facilities data remain largely fragmented: raw diagnostics are stored in ad hoc formats, material sample histories are disconnected from test conditions, and metadata standards are absent, precluding systematic cross-campaign analysis and long-term reuse. BEAST (Backend for Experiment Analysis, Storage, and Traceability) is an open-source, web-based platform that addresses these limitations by providing a unified, queryable infrastructure for high-enthalpy ground-test data [1]. First presented at the 15th Ablation Workshop [2], BEAST has since undergone significant development. The platform ingests and structures multi-channel time-series diagnostics, facility configurations, and material property records within a common provenance model, ensuring end-to-end traceability from raw sensor acquisition to reduced experimental quantities. A versioned material library links specimen identity and processing history to the specific runs in which each sample was tested. An integrated modeling workbench enables training and evaluation of regression models directly on archived experimental data, supporting condition interpolation and the construction of empirical material response databases. Beyond its original deployment at NASA Ames Research Center, BEAST has been designed to be facility-agnostic, with ongoing efforts to extend its adoption to other facilities. Its modular architecture accommodates heterogeneous diagnostic setups and facility types, and its future open-source distribution allows institutions to build on a common data standard rather than maintaining isolated, bespoke solutions. BEAST is further integrated within a broader ecosystem of companion tools: arcjetCV [3] extracts recession rates and shock standoff distances from high-speed video using computer vision, and miniSTARscan [4] provides sub-minute, portable photogrammetric surface reconstruction of test articles before and after exposure. All tools share a common data schema, enabling seamless ingestion of surface geometry, imagery, and time-series data into a single, coherent experimental record.

Database↗
NASA NTRSDate not supplied

Advancement of Entry System Modeling to Support Exploration of Giant Planets

This paper describes NASA’s efforts to advance entry system modeling and simulation capabilities to support future exploration of Giant planets. The Giant planets are key destinations of interest to the planetary science community for their potential to provide insight into the formation and evolution of our Solar System, as well as extrasolar planetary systems. To date, the Galileo atmospheric probe is the only purpose-built entry probe to a Giant planet. Post-flight analysis of Galileo’s performance showed that there was significant recession of the thermal protection system (TPS), well beyond what was anticipated on the flank, and this was due in part to insufficiently accurate capability for estimating the flight environment and TPS response. While Galileo ultimately survived its flight, the example serves to highlight the great challenge of designing successful missions for environments that are poorly understood or where models have not yet been validated. An important means to reduce mission risks is the incorporation of physics-based modeling with well-quantified uncertainties. The emphasis on physics-based modeling – in contrast to empirically-driven models – is motivated by the fact that it is impossible to completely replicate entry environments through ground tests and, therefore, extrapolation to the flight environment is required. Basing analysis in fundamental physics removes the bias of ground test limitations, though one must then be careful to properly characterize model inputs, simplifying assumptions, and the limits wherein the model is valid. NASA’s Entry Systems Modeling (ESM) Project is tasked with investigating such considerations for planetary science missions across the Solar System, and in recent years has begun to do so for Giant planets. The most distinctive features of the Giant planets, from an entry system perspective, are the atmospheres composed primarily of hydrogen and helium. The entry velocities of proposed missions are generally very large and can therefore be expected to result in significant convective and radiative heating generated by the vehicle’s shock layer. Yet thermochemical behavior of the hydrogen-helium system is not well understood under such conditions. The ESM project is leading efforts to develop accurate thermochemical databases based on state-of-the-art measurements in the Electric Arc Shock Tube and detailed computational chemistry. The large heat fluxes anticipated by missions has driven interest in new TPS materials, in particular woven materials, which may be enabling but have never been flown before. Consequently, multiscale models are in development to describe properties and performance of the materials from micro- to system-scale. The goal is to not only provide accurate thermal response but also to inform thermostructural reliability predictions for extreme entries. Additionally, new computational models have been developed to evaluate performance of non-destructive evaluation techniques which are vital to establishing acceptance of systems to be free of manufacturing faults like material cracking, voids, and debonding. Finally, in the area of guidance and control, aerocapture has been shown conceptually to provide a number of mission benefits, including reducing transit time and increasing payload fraction. The ESM project is building a launch-to-landing trajectory simulation capability to enable detailed studies of aerocapture maneuvers in the context of Giant planets missions. The final presentation and paper will describe each of these topics in detail, including discussion of specific gaps and the technical approach to solving them. In addition, the final paper will briefly discuss ongoing coordination between ESM project work and an ESA-funded technology development activity comprised of validation testing in the Oxford T6, IRS PWK and IST ESTHER tunnels, as well as state-to-state modeling of the shock layer to better represent non-Boltzmann energy distributions leading to non-equilibrium radiation.

Entry systems↗
NASA NTRSDate not supplied

Investigation of the effect of etch pits on the material properties of carbon fiber structures

It is well known that etch pits are formed on carbon surfaces during their consumption in reactive gas environments such as during ablation of carbon-based thermal protection system (TPS) materials. These pits start out from atomic defects on the carbon surface, grow in size and then ultimately lead to the complete removal of the solid carbon material [1, 2]. However, the effect of such etch pits on the material properties of carbon ablators such as FiberForm are poorly understood, as the maximum size of pits are on the order of microns in size, which makes them hard to observe experimentally. Hence, we have developed a module within the Porous Microstructure Analysis code PuMA [3] that can generate etch pits on an arbitrary material surface, with a prescribed distribution of pit size and density. Figure 1 shows a FiberForm sample with artificially generated pits of varying radii and pit density. We use this newly developed module to calculate material properties of FiberForm, which is the base material for one of the most commonly used TPS materials - Phenolic Impregnated Carbon Ablator (PICA). The detailed microstructure of FiberForm in PuMA will either be generated synthetically or obtained from X-ray microtomography [4]. Our simulations show that material properties such as the thermal conductivity and tortuosity decrease with increasing degree of pitting. This will be helpful to more accurately predict the degradation of carbon-based TPS during ablation, and furthermore may allow us to identify previously unknown TPS failure modes due to pitting.

PuMA↗
NASA NTRS2021

Temperature and Frequency Dependent Electrical Properties of AVCOAT and Shuttle Tile Material

This technical memorandum presents the data and results from a series of tests performed on AVCOAT, charred AVCOAT, and different Shuttle Thermal Protection System (TPS) tile coatings to determine their electrical properties as a function of temperature and frequency. Initially, the samples were assumed to be insulators and the complex permittivities were measured from data collected by sandwiching each sample between two conductors to form a sandwich. However, the AVCOAT sample data showed that the material becomes conductive as it begins to char. To get an accurate conductivity reading on these charred samples, a four-point resistance probe was used to collect data. Overall, this testing showed that the virgin AVCOAT starts out as a material that is a good insulator but transitions to one with a conductivity on the order of 1860 S/m as it chars. The deeper layers of AVCOAT (un-charred) all exhibited a temperature and frequency dependence that is possibly indicative of a dielectric relaxation in the material. As the sample temperatures were increased, a knee appears in the real permittivity data sets below 1 kHz. Both the real permittivity and resistivity drop up to several orders of magnitude yet show that the material remains an insulator. The Shuttle High Temperature Reusable Surface Insulation (HRSI) tile coatings studied included Reac- tion Cured Glass (RCG), Aluminum Enhanced Thermal Barrier (AETB), and Toughened Unipiece Fibrous Insulation (TUFI). The purely glass fiber parts of the tile were removed leaving only the outer layers con- taining just the coating. The data collected shows that the RCG, AETB, and outermost layer of the TUFI have similar electrical properties. The real permittivity plots show that there appears to be a relaxation that shows up at frequencies below 1 kHz. The relaxation frequency increases with increasing temperature. Also, the real permittivity increases up to about a factor of four between room temperature and 650K. Likewise, the resistivity (related to the imaginary permittivity) decreases up to five orders of magnitude over the same temperature interval, but still remains an insulator. This data was collected to support a NASA Engineering and Safety Center (NESC) assessment team investigating the source of thermocouple anomalies in both Shuttle TPS material and AVCOAT used for on the Orion spacecraft for Exploration Flight Test 1 (EFT-1). The details of their findings will be documented in a separate report with this document serving as a reference.

Mark A Nurge↗
NASA NTRS2019

The Dragonfly Entry and Descent System

Dragonfly is a proposed New Frontiers class mission that will send a nuclear powered octocopter to the surface of Titan for an extended science mission. This presentation will provide an overview of the Entry and Descent system that is under development to ensure the save delivery of this unique "relocatable lander" to Titan. Titan's dense atmosphere, large atmospheric scale height, and low gravity allows for a slow-paced entry and descent sequence that lasts more than 100 minutes, as opposed to the "7 minutes of terror" that is charac-teristic of landed Mars missions. This slow pace al-lows for sufficient temporal separation between critical events of the EDL sequence to minimize overall risk.The Dragonfly entry and descent system is composed of high-heritage components, minimizing overall risk. The aeroshell will be a scaled Genesis Sample Return capsule with a diameter of 3.75 meters, built by Lock-heed Martin. The thermal protection system (TPS) is made up of Phenolic Impregnated Carbon Ablator-Domestic (PICA-D) on the heatshield, SLA-561V on the backshell, and SLA-220M on the aft cover and low gain antenna. Each material has extensive heritage for the chosen application. The spacecraft will enter Titan at a velocity of 7.3 km/s, resulting in a predicted fully margined stagnation point heating environment of 254 W/cm2 heat rate and 13 kJ/cm2 heat load, well within the tested limits of the chosen materials. The aeroheat-ing environments, including the significant contribu-tion of shock layer radiation from CN on both the heatshield and backshell, are evaluated using state of the art models and codes that have been validated with appropriate ground testing.Once the deceleration pulse is complete, a disk-gap-band (DGB) drogue parachute will be deployed at ap-proximately Mach 1.5 to stabilize and further deceler-ate the spacecraft. Due to the dense atmosphere, the spacecraft will spend more than 80 minutes on this parachute, until reaching an appropriate altitude to de-ploy the subsonic main parachute. The lander is re-leased after approximately 17 minutes on the main chute before releasing and transitioning to powered flight in order to navigate to its first landing site. The release of the lander from the backshell effectively ends the entry and descent portion of the mission.The full presentation will provide additional details about the design of the EDL system hardware, engi-neering design, and overall con-ops. Preliminary aero-thermal and TPS sizing analyses will be presented, and the parachute system will be described in greater detail. In addition, the Dragonfly spacecraft will carry an En-gineering Science Investigation (ESI) package designed to obtain engineering data during EDL that will be used to validate the design methodology for future missions. An overview of the proposed ESI package will also be presented.

EDL↗
NASA NTRS2021

Overview of Dragonfly Entry Aerosciences Measurements (DrEAM)

NASA Ames Research Center (ARC) leads the Dragonfly Entry Aerosciences Measurements (DrEAM) project, which is an aeroshell instrumentation suite on the Dragonfly mission that fulfills the Engineering Science Investigation requirement for the New Frontiers mission. NASA ARC is partnering with NASA Langley Research Center (LaRC) and the German Aerospace Center (DLR) to provide a comprehensive sensor suite, including a DLR-provided Data Acquisition System (DAS). DrEAM will provide key aerothermodynamic data and performance analysis for Dragonfly’s forebody and backshell Thermal Protection System (TPS). Titan’s atmosphere predominantly consists of ni-trogen (~98% by mole) with small amounts of me-thane (~2% by mole) and other trace gases. CN is a strong radiator, and is found in nonequilibrium con-centrations for Titan entry. The accurate modeling of nonequilibrium CN radiation has proven to be a diffi-cult task. Prompted by the Huygens mission, many experimental campaigns and analyses were performed to better understand the aerothermal environments experienced by the probe during Titan entry [1]. How-ever, the Huygens probe carried no heatshield instru-mentation. Therefore, the DrEAM sensor suite will sig-nificantly advance the state-of-the-art not only by documenting the environment and performance of Dragonfly’s entry system but also by making key in situ measurements in Titan’s atmosphere for the first time. Aerothermal environments and TPS response will be measured using sensors whose flight heritage is tak-en from the Mars Entry, Descent, and Landing In-strumentation 2 (MEDLI2) thermocouple plugs and the COMbined Aerothermal and Radiometer Sensor (COMARS) suite [2], with the latter supplied by DLR. The MEDLI2 project used embedded thermocouples to directly measure the in-depth TPS temperature-time history at several locations on the heat shield and backshell of the Mars 2020 entry vehicle. These tem-perature measurements, in turn, can be used to infer surface environments via an inverse analysis proce-dure analogous to that used for MEDLI. For DrEAM, the thermocouple plug subsystem will be known as Dragonfly Sensors for Aero-Thermal Reconstruction (DragSTR). On Schiaparelli, the COMARS suite in-cluded three total surface-mounted heat flux sensors, three pressure sensors, and one radiometer. For DrEAM, the COMARS package will be known as the COmbined Sensor System for Titan Atmosphere (COSSTA). Since the methane concentration in the Titan atmos-phere is directly proportional to the radiative heat flux, the COSSTA measurements will be used to reduce the current uncertainty in the methane volume fraction. Atmospheric density measurements and capsule aero-dynamic data will be obtained through the onboard Inertial Measurement Unit (IMU), supplemented by pressure transducers similar to those used by the MEDLI and MEDLI2 projects. The DrEAM pressure sensors will be known as the Dragonfly Atmospheric Flight Transducers. (DrAFT). The pressure measure-ments, when combined with data from the on-board IMU, will allow for reconstruction of such quantities as vehicle Mach number, freestream density, and atmos-pheric winds. DrAFT measurements will enhance Dragonfly trajectory reconstruction and enable a sepa-ration of the aerodynamics from the atmosphere, as was done for MEDLI [3] and is currently in process for the MEDLI2 flight data set.

EDL↗
NASA NTRSDate not supplied

Reconstruction of Thermal Protection System Aeroheating using a Green’s Function Approach

Inverse heat transfer (IHT) techniques are often used to reconstruct the surface heating conditions on spacecraft thermal protection systems (TPS) during atmospheric entry. Current IHT techniques for entry spacecraft applications, however, demand substantial computational resources, and are impractical for analyses such as uncertainty quantification and real-time health monitoring. In this paper, a Green’s function sensor fusion approach is used to reconstruct the TPS surface aeroheating conditions on experimental spaceflight and ground test systems from collocated temperature and heat flux sensors embedded in the TPS. The algorithm leverages Green’s functions to model the heat conduction within the spacecraft TPS and stabilizes the recovery of the surface heating condition using the direct heat flux sensor measurement. The algorithm is validated using arc-jet ground test data and applied to the reconstruction of the Mars 2020 backshell heating during Martian atmospheric entry. The performance of the algorithm is benchmarked against a current state-of-the-art IHT framework, FIAT_Opt. The Green’s function-based reconstruction algorithm recovers the net hot-wall heat flux absorbed by the TPS and the incident heat flux from the atmospheric entry environment in close agreement with FIAT_Opt. Notably, computation of the surface heating condition is completed in three orders of magnitude less time with the Green’s function sensor fusion approach using a consumer-grade PC, versus with FIAT_Opt running on a high performance computer cluster. The efficiency of the algorithm is leveraged to compute the uncertainty contributions of input parameters to the total uncertainty in reconstructed Mars 2020 backshell heating for the full atmospheric entry heat pulse. The sensitivity analysis uncovers that, at different times throughout the entry heat pulse, uncertainties in the TPS specific heat, thermal conductivity, and emissivity are all dominant drivers of the reconstruction uncertainty. These results demonstrate Green’s functions and sensor-fusion techniques as promising IHT approaches to reconstruct atmospheric entry environments from TPS-embedded measurements, and highlight how these techniques may give access to post-flight analyses previously hindered by the prohibitive cost of current methods.

Kenneth McAfee↗
NASA NTRSDate not supplied

Reconstruction of Thermal Protection System Aeroheating using a Green’s Function Approach

Inverse heat transfer (IHT) techniques are often used to reconstruct the surface heating conditions on spacecraft thermal protection systems (TPS) during atmospheric entry. Current IHT techniques for entry spacecraft applications, however, demand substantial computational resources, and are impractical for analyses such as uncertainty quantification and real-time health monitoring. In this paper, a Green’s function sensor fusion approach is used to reconstruct the TPS surface aeroheating conditions on experimental spaceflight and ground test systems from collocated temperature and heat flux sensors embedded in the TPS. The algorithm leverages Green’s functions to model the heat conduction within the spacecraft TPS and stabilizes the recovery of the surface heating condition using the direct heat flux sensor measurement. The algorithm is validated using arc-jet ground test data and applied to the reconstruction of the Mars 2020 backshell heating during Martian atmospheric entry. The performance of the algorithm is benchmarked against a current state-of-the-art IHT framework, FIAT_Opt. The Green’s function-based reconstruction algorithm recovers the net hot-wall heat flux absorbed by the TPS and the incident heat flux from the atmospheric entry environment in close agreement with FIAT_Opt. Notably, computation of the surface heating condition is completed in three orders of magnitude less time with the Green’s function sensor fusion approach using a consumer-grade PC, versus with FIAT_Opt running on a high performance computer cluster. The efficiency of the algorithm is leveraged to compute the uncertainty contributions of input parameters to the total uncertainty in reconstructed Mars 2020 backshell heating for the full atmospheric entry heat pulse. The sensitivity analysis uncovers that, at different times throughout the entry heat pulse, uncertainties in the TPS specific heat, thermal conductivity, and emissivity are all dominant drivers of the reconstruction uncertainty. These results demonstrate Green’s functions and sensor-fusion techniques as promising IHT approaches to reconstruct atmospheric entry environments from TPS-embedded measurements, and highlight how these techniques may give access to post-flight analyses previously hindered by the prohibitive cost of current methods.

Kenneth McAfee↗
NASA NTRS2017

Inviscid/Boundary-Layer Aeroheating Approach for Integrated Vehicle Design

A typical entry vehicle design depends on the synthesis of many essential subsystems, including thermal protection system (TPS), structures, payload, avionics, and propulsion, among others. The ability to incorporate aerothermodynamic considerations and TPS design into the early design phase is crucial, as both are closely coupled to the vehicle's aerodynamics, shape and mass. In the preliminary design stage, reasonably accurate results with rapid turn-representative entry envelope was explored. Initial results suggest that for Mach numbers ranging from 9-20, a few inviscid solutions could reasonably sup- port surface heating predictions at Mach numbers variation of +/-2, altitudes variation of +/-10 to 20 kft, and angle-of-attack variation of +/- 5. Agreement with Navier-Stokes solutions was generally found to be within 10-15% for Mach number and altitude, and 20% for angle of attack. A smaller angle-of-attack increment than the 5 deg around times for parametric studies and quickly evolving configurations are necessary to steer design decisions. This investigation considers the use of an unstructured 3D inviscid code in conjunction with an integral boundary-layer method; the former providing the flow field solution and the latter the surface heating. Sensitivity studies for Mach number, angle of attack, and altitude, examine the feasibility of using this approach to populate a representative entry flight envelope based on a limited set of inviscid solutions. Each inviscid solution is used to generate surface heating over the nearby trajectory space. A subset of a considered in this study is recommended. Results of the angle-of-attack sensitivity studies show that smaller increments may be needed for better heating predictions. The approach is well suited for application to conceptual multidisciplinary design and analysis studies where transient aeroheating environments are critical for vehicle TPS and thermal design. Concurrent prediction of aeroheating environments, coupled with the use of unstructured methods, is considered enabling for TPS material selection and design in conceptual studies where vehicle mission, shape, and entry strategies evolve rapidly.

Lee, Esther↗
NASA NTRSDate not supplied

Probabalistic Risk Analysis and Thermal Margin Process for an Inflatable Aeroshell

Uncertainties always exist in atmospheric entry aeroheating environments and the thermal response of thermal protection system (TPS) material. These uncertainties are mitigated in the design by ap-plying margin and factors of safety to the TPS. Entry vehicle TPS is often conservatively over-sized for the heat loads that are experienced along the entry trajectory by stacking worst-case scenarios together. Additionally, the current TPS design and margin process used by NASA offers very little insight into the risk of over-temperature during flight and the reliability of the heat shield performance [1,3]. A probabilistic margin process can be used to calculate the amount of TPS margin necessary to survive a given entry heat load at a specified level of risk [2,3,4]. The vehicle’s initial entry state (entry velocity, flight path angle, and entry mass) determines the expected atmospheric entry environmental conditions and resulting heat load that the entry vehicle will experience. If there is flexibility in the entry state, then this process can be used to select an appropriate combination of entry state parameters and TPS size to target a desired reentry reliability. This probabilistic margin process allows engineers to make informed aeroshell design, entry-trajectory design, and TPS performance risk trades while preventing excessive TPS margin from being applied. The probabilistic TPS margin process has been performed to determine TPS thickness and entry heating constraints given an acceptable risk level for the Low Earth Orbit Flight Experiment of an Inflatable Decelerator (LOFTID) flight project. The process is used in a manner to size the entry heat load for a given flexible TPS (FTPS) thickness so that it meets project reliability standards while allowing the FTPS and the underlying inflatable structure (IS) to be pushed to adequately high temperatures. Since the LOFTID project is an experimental flight demonstration, it is de-sired to drive the FTPS and IS to temperatures that cover a large range of their thermal response models’ applicability. This will allow the thermal response models to be better improved and validated post-flight using LOFTID’s extensive instrumentation embedded within the aeroshell. The presentation demonstrates how uncertainty analysis is carried out using an end-to-end Monte Carlo process where three separate Monte Carlo simulations are run in sequence. The first Monte Carlo simulation operates on the entry trajectory model to generate trajectory parameter dispersions that are fed into the second Monte Carlo simulation. The second Monte Carlo simulation operates on the aerothermodynamics model to generate aeroheating parameter dispersions that are fed into the third Monte Carlo simulation. The third Monte Carlo simulation operates on the FTPS material thermal response model to generate the final FTPS/IS thermal response dispersions. The end-to-end Monte Carlo simulation propagates the uncertainties of each model into the next to quantify the resulting uncertainty of the FTPS/IS thermal response. The fractional contributions of the uncertain parameters in the trajectory, aerothermal, and thermal response models to the variance in the FTPS/IS thermal response is determined as a byproduct of the Monte Carlo analysis. The structural uncertainty of the FTPS thermal response model is evaluated by flight relevant ground testing and model error analysis using test measurements. This probabilistic TPS margin process had never been applied to an entry vehicle and it is one of the LOFTID project’s goals to demonstrate its merits.

Steven A. Tobin↗
NASA NTRS2005

High-Temperature Structures, Adhesives, and Advanced Thermal Protection Materials for Next-Generation Aeroshell Design

The next generation of planetary exploration vehicles will rely heavily on robust aero-assist technologies, especially those that include aerocapture. This paper provides an overview of an ongoing development program, led by NASA Langley Research Center (LaRC) and aimed at introducing high-temperature structures, adhesives, and advanced thermal protection system (TPS) materials into the aeroshell design process. The purpose of this work is to demonstrate TPS materials that can withstand the higher heating rates of NASA's next generation planetary missions, and to validate high-temperature structures and adhesives that can reduce required TPS thickness and total aeroshell mass, thus allowing for larger science payloads. The effort described consists of parallel work in several advanced aeroshell technology areas. The areas of work include high-temperature adhesives, high-temperature composite materials, advanced ablator (TPS) materials, sub-scale demonstration test articles, and aeroshell modeling and analysis. The status of screening test results for a broad selection of available higher-temperature adhesives is presented. It appears that at least one (and perhaps a few) adhesives have working temperatures ranging from 315-400 C (600-750 F), and are suitable for TPS-to-structure bondline temperatures that are significantly above the traditional allowable of 250 C (482 F). The status of mechanical testing of advanced high-temperature composite materials is also summarized. To date, these tests indicate the potential for good material performance at temperatures of at least 600 F. Application of these materials and adhesives to aeroshell systems that incorporate advanced TPS materials may reduce aeroshell TPS mass by 15% - 30%. A brief outline is given of work scheduled for completion in 2006 that will include fabrication and testing of large panels and subscale aeroshell test articles at the Solar-Tower Test Facility located at Kirtland AFB and operated by Sandia National Laboratories. These tests are designed to validate aeroshell manufacturability using advanced material systems, and to demonstrate the maintenance of bondline integrity at realistically high temperatures and heating rates. Finally, a status is given of ongoing aeroshell modeling and analysis efforts which will be used to correlate with experimental testing, and to provide a reliable means of extrapolating to performance under actual flight conditions. The modeling and analysis effort includes a parallel series of experimental tests to determine TSP thermal expansion and other mechanical properties which are required for input to the analysis models.

Collins, Timothy J.↗
NASA NTRS1998

Measuring Thermal Conductivity and Moisture Absorption of Cryo-Insulation Materials

NASA is seeking to develop thermal insulation material systems suitable for withstanding both extremely high temperatures encountered during atmospheric re-entry heating and aero- braking maneuvers, as well as extremely low temperatures existing in liquid fuel storage tanks. Currently, materials used for the high temperature insulation or Thermal Protection System (TPS) are different from the low temperature, or cryogenic insulation. Dual purpose materials are necessary to the development of reusable launch vehicles (RLV). The present Space Shuttle (or Space Transportation System, STS) employs TPS materials on the orbiter and cryo-insulation materials on the large fuel tank slung under the orbiter. The expensive fuel tank is jettisoned just before orbit is achieved and it burns up while re-entering over the Indian Ocean. A truly completely reusable launch vehicle must store aR cryogenic fuel internally. The fuel tanks will be located close to the outer surface. In fact the outer skin of the craft will probably also serve as the fuel tank enclosure, as in jet airliners. During a normal launch the combined TPS/cryo-insulation system will serve only as a low temperature insulator, since aerodynamic heating is relatively minimal during ascent to orbit. During re-entry, the combined TPS/cryo-insulation system will serve only as a high temperature insulator, since all the cryogenic fuel will have been expended in orbit. However, in the event of an.aborted launch or a forced/emergency early re-entry, the tanks will still contain fuel, and the TPS/cryo-insulation will have to serve as both low and high temperature insulation. Also, on long duration missions, such as to Mars, very effective cryo-insulation materials are needed to reduce bod off of liquid propellants, thereby reducing necessary tankage volume, weight, and cost. The conventional approach to obtaining both low and high temperature insulation, such as is employed for the X-33 and X-34 spacecraft, is to use separate TPS and cryo-insulation materials, which are connected by means of adhesives or stand-offs (spacers). Three concepts are being considered: (1) the TPS is bonded directly to the cryo-insulation which, in turn, is bonded to the exterior of the tank, (2) stand-offs are used to make a gap between the TPS and the cryo-insulation, which is bonded externally to the tank, (3) TPS is applied directly or with stand-offs to the exterior so the tank, and cryo-insulation is applied directly to the interior of the tank. Many potential problems are inherent in these approaches. For example, mismatch between coefficients of thermal expansion of the TPS and cryo-insulation, as well as aerodynamic loads, could lead to failure of the bond. Internal cryo-insulation must be prevent from entering the sump of the fuel turbo-pump. The mechanical integrity of the stand-off structure (if used) must withstand multiple missions. During ground hold (i.e., prior to launch) moisture condensation must be minimized in the gap between the cryo-insulation and the TPS. The longer term solution requires the development of a single material to act as cryo- insulation during ground hold and as TPS during re-entry. Such a material minimizes complexity and weight while improving reliability and reducing cost.

Lambert, Michael A.↗
NASA NTRSDate not supplied

High-Enthalpy Testing to Validate Simulation of an Aerosol Capture Probe

AERACEPT (Aerosol Rapid Analysis Combined Entry Probe/sonde Technology) is a developing technology enabling in-situ aerosol particle sampling and analysis in a small spacecraft mission envelope. It integrates a passive aerosol sample collection system into a probe’s thermal protection system (TPS) to remove the need for heat shield separation and active descent control (parachutes, gliders, etc.). AERACEPT is being validated against the requirements of the Nephele mission concept, which targets the middle and lower Venus cloud layers. The proposed technology employs 3D Carbon-Carbon (3D-CC) at the probe’s nose to withstand the extreme environments encountered in a Venus entry without producing pyrolysis gases that would contaminate the mission sample collection. Any shape change of this 3D-CC sample inlet will affect airflow through the sampling system, thereby impacting aerosol sample collection bias and efficiency. Accurate prediction of the nose’s material response during entry is there-fore of fundamental importance to the development and practical use of this technology. As a result, the AERACEPT project is planning a test campaign in the newly built PlasmatronX facility with a novel “Open Iso-Q” test article to validate state-of-the-art material response tools for a simulated Venus entry. The PlasmatronX is a 350 kW inductively-coupled plasma facility developed and run by the Center for Hypersonics and Entry Systems Studies at the University of Illinois at Urbana-Champaign. The facility can support ground testing for a variety of planetary destinations by simulating entry conditions in Nitrogen, Air, and Carbon Dioxide. To best simulate the Venus atmosphere and match flight-like recession, the planned AERACEPT test campaign will use Carbon Dioxide as its test gas. AERACEPT has designed two test articles for this campaign: 1) a standard test article whose curved surface approximates a constant applied heat flux (“Closed Iso-Q” model) and 2) a novel inlet test article with a through-hole at the stagnation point (“Open Iso-Q” model). Both article types consist of a 3D-CC sample bonded to a graphite fixture. All articles will be laser scanned before and after testing to estimate shape change and recession, and the “Closed Iso-Q” articles will be instrumented with thermocouples to provide temperature histories. The test article temperatures and inlet shape change will be compared against simulations run with the Porous material Analysis Toolbox based on OpenFOAM (PATO) to validate the AERACEPT 3D-CC material response model. Due to the high thermal conductivity of 3D-CC, multidimensional effects have a large influence on the test article temperature and the standard 1-D material response tools are not sufficient for test planning. The test campaign features (e.g. article design, run duration, heat fluxes) are therefore informed by a series of 3-D simulations using state-of-the-art material response tools such as PATO. The test campaign is scheduled for spring of 2024. Expected results include 1) Key drivers of selected test conditions (e.g. matching mission flight atmosphere & recession), 2) Simulation results that informed test article design, 3) Acquired test data such as recession measurements, temperature histories, and photos, and 4) Comparisons between test results and simulation predictions.

AERACEPT↗
NASA NTRSDate not supplied

High-Enthalpy Testing to Validate Simulation of an Aerosol Capture Probe

AERACEPT (Aerosol Rapid Analysis Combined Entry Probe/sonde Technology) is a developing technology enabling in-situ aerosol particle sampling and analysis in a small spacecraft mission envelope. It integrates a passive aerosol sample collection system into a probe’s thermal protection system (TPS) to remove the need for heat shield separation and active descent control (parachutes, gliders, etc.). AERACEPT is being validated against the requirements of the Nephele mission concept, which targets the middle and lower Venus cloud layers. The proposed technology employs 3D Carbon-Carbon (3D-CC) at the probe’s nose to withstand the extreme environments encountered in a Venus entry without producing pyrolysis gases that would contaminate the mission sample collection. Any shape change of this 3D-CC sample inlet will affect airflow through the sampling system, thereby impacting aerosol sample collection bias and efficiency. Accurate prediction of the nose’s material response during entry is there-fore of fundamental importance to the development and practical use of this technology. As a result, the AERACEPT project is planning a test campaign in the newly built PlasmatronX facility with a novel “Open Iso-Q” test article to validate state-of-the-art material response tools for a simulated Venus entry. The PlasmatronX is a 350 kW inductively-coupled plasma facility developed and run by the Center for Hypersonics and Entry Systems Studies at the University of Illinois at Urbana-Champaign. The facility can support ground testing for a variety of planetary destinations by simulating entry conditions in Nitrogen, Air, and Carbon Dioxide. To best simulate the Venus atmosphere and match flight-like recession, the planned AERACEPT test campaign will use Carbon Dioxide as its test gas. AERACEPT has designed two test articles for this campaign: 1) a standard test article whose curved surface approximates a constant applied heat flux (“Closed Iso-Q” model) and 2) a novel inlet test article with a through-hole at the stagnation point (“Open Iso-Q” model). Both article types consist of a 3D-CC sample bonded to a graphite fixture. All articles will be laser scanned before and after testing to estimate shape change and recession, and the “Closed Iso-Q” articles will be instrumented with thermocouples to provide temperature histories. The test article temperatures and inlet shape change will be compared against simulations run with the Porous material Analysis Toolbox based on OpenFOAM (PATO) to validate the AERACEPT 3D-CC material response model. Due to the high thermal conductivity of 3D-CC, multidimensional effects have a large influence on the test article temperature and the standard 1-D material response tools are not sufficient for test planning. The test campaign features (e.g. article design, run duration, heat fluxes) are therefore informed by a series of 3-D simulations using state-of-the-art material response tools such as PATO. The test campaign is scheduled for spring of 2024. Expected results include 1) Key drivers of selected test conditions (e.g. matching mission flight atmosphere & recession), 2) Simulation results that informed test article design, 3) Acquired test data such as recession measurements, temperature histories, and photos, and 4) Comparisons between test results and simulation predictions.

AERACEPT↗
NASA NTRS2012

SRMS Assisted Docking and Undocking for the Orbiter Repair Maneuver

As part of the Orbiter Repair Maneuver (ORM) planned for Return to Flight (RTF) operations, the Shuttle Remote Manipulator System (SRMS) must undock the Orbiter, maneuver it through a complex trajectory at extremely low rates, present it to an EVA crewman at the end of the Space Station Remote Manipulator System to perform the Thermal Protection System (TPS) repair, and then retrace back through the trajectory to dock the Orbiter with the Orbiter Docking System (ODS). The initial and final segments of this operation involve the interaction between the SRMS, ISS, Orbiter and ODS. Previously, a technique entitled "SRMS assisted docking" for installation of a payload to the ODS had been developed and was utilized for the Russian provided Docking Module on STS-74 during Shuttle-Mir missions and both the Node 1 and FGB elements on STS-88/Flight 2A. This procedure consisted of the SRMS grappling the respective payload, maneuvering it to a pre-install position inches above the ODS Androgynous Peripheral Attachment System (APAS) ring, commanding the SRMS into Test mode (which allows brakes-off motion of the joints), and then down-firing Primary Reaction Control System (PRCS) jets in order to effect a capture of the APAS latches. Once a successful capture had been achieved, then the AP AS was operated through its nominal retraction sequence to complete the mating sequence. While this technique can once again be used for the tail end docking portion of the ORM, the initial undocking of the orbiter and ISS vehicles with the assistance of the SRMS has yet to be attempted on orbit. The objective here is to determine the most efficient means to separate or extract the vehicles. Two techniques were analyzed in support of RTF: (1) the 'nominal' demating from the mated interface, and (2) the SRMS performing the operation (either in an active or passive fashion). In the first operation, the demating process would replicate standard undocking operations, with the exception that the SRMS is allowed to arrest the resulting motion. The second operation would be to extend the APAS ring to a ready to dock position, open the capture latches, and then detach the vehicles using the SRMS either actively or passively. In the active case, the APAS ring is extended and latched, and the SRMS is commanded to pull the two interfaces apart (assuming that the effective pull force of the SRMS can overcome the spec values of the combined latch resistance). In the passive case, the SRMS brakes are engaged and the AP AS mechanism is commanded to retract, pulling the two interfaces apart. Since the emphasis of both STS-74 and STS-88 had solely been on the installation operation, as opposed to the separation operation, two new models required development and incorporation within simulation tools designed to analyze those scenarios. These enhancements included: (1) a detailed demating dynamics model to characterize the pusher spring characteristics during undocking, and (2) contact and mechanical system modeling of the back side of the latches to represent unlatching dynamics. This paper first provides an overview of the Monte-Carlo screening analysis for the installation (both nominal and contingency), including the variation of separation distance, misalignment conditions, SRMS joint/brake parameter characteristics, and PRCS jet combinations and corresponding thrust durations. The resulting 'optimum' solution is presented based on trade studies between predicted capture success and integrated system loads. This paper then discusses the upgrades to the APAS math model associated with the new SRMS assisted undocking technique and reviews simulation results for various options investigated for either the active and passive separation of the ISS from the Orbiter.

Space Station Remote Manipulator System↗
NASA NTRS2019

InSight's Reconstructed Aerothermal Environments

The InSight Mars Lander successfully landed on the surface on November 26, 2018. This poster will describe the methodologies and margins used in developing the aerothermal environments for design of the thermal protection systems (TPS), as well as a prediction of as-flown environments based on the best estimated trajectory. The InSight mission spacecraft design approach included the effects of radiant heat flux to the aft body from the wake for the first time on a US Mars Mission, due to overwhelming evidence in ground testing for the European ExoMars mission (2009/2010) [1] and 2010 tests in the Electric Arc Shock Tube (EAST) facility [2]. The radiant energy on an aftbody was also recently confirmed via measurement on the Schiaparelli mission [3]. In addition, the InSight mission expected to enter the Mars atmosphere during the dust storm season, so the heatshield TPS was designed to accommodate the extra recession due to the potential dust impact. This poster will compare the predicted aerothermal environments using the reconstructed best estimated trajectory to the design environments. Design Approach: The InSight spacecraft was planned to be a near-design-to-print copy of the Phoenix spacecraft. The determination of the heatshield TPS requirements was approached as if it was a new design due to the new requirement of flying through a dust storm. The baseline for aftbody was build-to-print, and all analyses focused on ensuring adequate margin. This proved to be a challenge because the Phoenix aftbody was designed to withstand only convective heating and the InSight aftbody was evaluated for both convective and radiative heating. Aerothermal environments were predicted using the Langley Aerothermodynamic Upwind Relaxation Algorithm (LAURA) and the Data Parallel Line Relaxation (DPLR) CFD codes, and the Nonequilibrium Radiative Transport and Spectra Program (NEQAIR) utilizing bounding design trajectories derived from Monte Carlo analyses from the Program to Optimize Simulated Trajectories II (POST2). In all cases, super-catalytic flowfields were assigned to ensure the most conservative heating results. Two trajectories were evaluated: 1) the trajectory with the maximum heat flux was utilized to determine the flowfield characteristics and the viability of the selection of TPS materials; and 2) the trajectory with the maximum heat load was used to determine the required thicknesses of the TPS materials. Evaluation of the MEDLI data [4], along with ground test data [5] led to the determination of whether or not the flow would transition from laminar to turbulent on the heatshield, which also determined the TPS sizing location for the heatshield. Aerothermal margins were added for the convective heating and developed for the radiative heating. TPS material sizing was determined with the Reaction Kinetic Ablation Program (REKAP) and the Fully Implicit Ablation and Thermal Analysis program (FIAT) using a three-branched approach to account for aerothermal, material response, and material properties uncertainties. In addition, the heatshield recession was augmented by an analysis of the effect of entry through a potential dusty atmosphere using a methodology developed in References [6] and [7]. These analyses resulted in an increase to the Phoenix heatshield TPS thickness. Reconstruction Efforts: Once the best estimated trajectory is reconstructed by the team, the LAURA/HARA (High-Temperature Aerothermo-dynamic Radiation model) and DPLR/NEQAIR code pairs will be used to predict the as-flown aerothermal conditions. In these runs, fully-catalytic flowfields will be assigned because it is a more physically accurate description of the chemistry in the flow. Once again, determination of the onset of turbulence on the heatshield will be evaluated. The as-flown aerothermal environments will then be compared to the design environments.

Beck, R. A.↗
DOE OSTI2023

Enhanced flexibility and thermal conductivity of HfC decorated carbon nanofiber mats

Future-generation spacecraft components allude discovery of novel materials that can withstand extreme environments (>2000 °C). The combined effect of ultra-high temperature ceramics (UHTCs) and carbon fibers (C f ) can satisfy the demanding requirements of aerospace applications. A novel, hybrid, and flexible hafnium carbide (HfC)-decorated carbon nanofiber (C nf ) mat was fabricated via electrospinning. Enhanced thermal stability of the flexible HfC decorated C nf over C nf can be elucidated from the 20-fold increment in thermal conductivity and the onset of degradation at higher temperatures (840 °C). Successful integration of multi-layered sandwich lattice using in-housed fabricated HfC decorated C nf showed retention of the fibrous structure even after extreme spark plasma sintering (SPS) process at 1850 °C. Fabricating a similar multi-layered structure using procured C f was unsuccessful due to bundled agglomeration and micron-sized fibers. High-load indentation suggests that HfC decorated C nf interlayer is stronger (~2.3 times) than the parent UHTC with no cracking at the interface. Compared with the HfC matrix, the indentation-damaged area at the interface reduced up to ~56% due to toughening mechanisms such as C nf , fiber pull-out and bridging. The synthesized HfC decorated Cnf mat is proposed as an ultra-thin filler material for joining similar or dissimilar UHTCs while maintaining similar chemistry and better mechanical integrity at the interface. Furthermore, the findings insinuate a new paradigm in designing hybrid and flexible ceramic-containing materials for thermal protection systems (TPS) of future-generation spacecraft components that can mitigate failure in extreme environments (>2000 °C).

36 MATERIALS SCIENCE↗