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At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
NASA NTRS1981

Unsteady environments and responses of the shuttle combined loads orbiter test

Both separate and combined wind tunnel and vibration shaker tests were conducted on two structural panels representative of the Shuttle orbiter in the NASA LaRC 8-foot transonic pressure tunnel (TPT) to determine the effects of combined loads on the thermal protection system (TPS). The primary objective of this test was to provide a combined full-scale load environment and realistic time history of the dynamic pressures, Mach numbers (through transonic), and dynamic structural responses of these panels. The panels were selected from orbiter locations where interactive load sources such as aerodynamic shock waves, turbulent boundary layers, strut-induced vorticity, and substrate deformation combined to provide high bonding loads between the TPS and the orbiter structure. The test panels for this program were highly instrumented with static and dynamic pressure gages, accelerometers, deflectometers, strain gages, Schileren and high-speed photography, and special instrumentation necessary to determine TPS/structure interface loads and tile motions. Two test specimens of each orbiter panel were utilized. Both were high-fidelity representations of the selected orbiter location. The first panel (calibration panel) for each test was utilized to calibrate the tunnel and shaker system as well as provide a data-gathering source for applied static and dynamic loads. The second panel (test panel) for each test was subjected to flight time exposures only so that TPS characteristics as a function of flight mission exposure could be determined. These tests were the last in a series that was suce6ssfully completed and necessary to certify the TPS prior to the first launching of the Shuttle.

P. H. Schuetz↗
NASA NTRS1983

Orbiter Entry Heating Lessons Learned from Development Flight Test Program

The Space Shuttle orbiter's thermal protection system (TPS), designed mainly on the basis of wind tunnel test data, has successfully completed its design, development, and flight test program. The flight test data provide an exceptional opportunity to evaluate the use of wind tunnel test data for the design of TPS for reentry vehicles. Comparisons of flight test data against wind tunnel data used to design the orbiter's TPS were developed. These flight data, though still in the preliminary analysis phases, generally support the use of wind tunnel test data in the design of TPS for hypersonic reentry vehicles.

Haney, J. W., Jr.↗
NASA NTRS1983

Life considerations of the shuttle orbiter densified-tile thermal protection system

The Shuttle orbiter themal protection system (TPS) incorporates ceramic reusable surface insulation tiles bonded to the orbiter substructure through a strain isolation pad. Densification of the bonding surface of the tiles increases the static strength of the tiles. The densification proces does not, however, necessarily lead to an equivalent increase in fatigue strength. Investigation of the expected lifetime of densified tile TPS under both sinusoidal loading and random loading simulating flight conditions indicates that the strain isolation pads are the weakest components of the TPS under fatigue loading. The felt pads loosen under repetitive loading and, in highly loaded regions, could possibly cause excessive step heights between tiles causing burning of the protective insulation between tiles. A method of improving the operational lifetime of the TPS by using a strain isolation pad with increased stiffness is presented as is the consequence of the effect of increased stiffness on the tile inplane strains and transverse stresses.

Cooper, P. A.↗
NASA NTRS1984

Aerothermodynamic environment and thermal protection for a Titan aerocapture vehicle

This paper presents thermal protection system (TPS) requirements for a potential Titan aerocapture vehicle. Shock-layer solutions are obtained for a nominal trajectory through the current Titan model atmosphere. Fully laminar and fully turbulent solutions are presented along the blunted fore-cone in the windward symmetry plane of a bent-biconic vehicle. Using these solutions to define the aerothermodynamic environment, transient material-response solutions are obtained for a Galileo-type TPS with a carbon-phenolic ablator heat shield. Shock-layer results indicate that turbulent flow is the more realistic flow condition. They also show that the lengthy aerocapture heating pulse is dominated by convective heating. The TPS results show that the required insulation thickness is uniformly about 4 cm along the fore-cone because of the long heat-soak period. The total heat-shield thickness is 6.4 cm at the stagnation point, and 4.7 cm near the end of the fore-cone. These TPS requirements are greater than those presented in a previous Titan aerocapture study.

Green, M. J.↗
NASA NTRS1985

Impacts of Space Shuttle thermal protection system tile on F-15 aircraft vertical tile

Impacts of the space shuttle thermal protection system (TPS) tile on the leading edge and the side of the vertical tail of the F-15 aircraft were analyzed under different TPS tile orientations. The TPS tile-breaking tests were conducted to simulate the TPS tile impacts. It was found that the predicted tile impact forces compare fairly well with the tile-breaking forces, and the impact forces exerted on the F-15 aircraft vertical tail were relatively low because a very small fraction of the tile kinetic energy was dissipated in the impact, penetration, and fracture of the tile. It was also found that the oblique impact of the tile on the side of the F-15 aircraft vertical tail was unlikely to dent the tail surface.

Ko, W. L.↗
NASA NTRS1985

Origin and development of ablator for Space Shuttle external tank

The Space Shuttle External Tank (ET) represents the largest element of the Space Shuttle transportation system. The ET is the fuel tank which contains cryogenic propellants, including liquid oxygen and liquid hydrogen. The task of providing a suitable Thermal Protection System (TPS) which is mass producible for the ET represented a challenge for the aerospace industry. The difficulties were compounded by stringent insulation and ablation requirements for the materials to maintain their integrity over a wide range of operating temperatures during prelaunch and ascent. Attention is given to the configuration of the Space Shuttle system, the configuration of the external tank, the initial ET TPS concept, TPS materials and processes concepts, design rationale, TPS materials structural considerations, material and processes development, development tests, material/process verification, and flight results.

Ronquillo, L.↗
NASA NTRS1993

Aerothermodynamic performance and thermal protection design for blunt re-entry bodies at L/D = 0.3

Aerodynamic heating and thermal protection design analyses were performed for three blunt re-entry bodies at an L/D = 0.3 returning from low earth orbit. These configurations consisted of a scaled up Apollo command module, a Viking re-entry vehicle, and an Aeroassist Flight Experiment (AFE) aerobrake, each with a maximum diameter of 4.42 m. The aerothermodynamic analysis determined the equilibrium stagnation point heating rate and heat load for nominal and 3-sigma re-entry trajectories and the distribution of heating along the pitch and yaw planes for each of the vehicles at the time of highest heat flux. Using the predicted heating rates and heating distributions, a Thermal Protection System (TPS) design with flight certified materials was tailored for each of the configurations. Results indicated that the heating to the corner of the Viking aeroshell would exceed current limits of reusable tile material. Also, the maximum heating for the AFE would be 15 percent greater than the maximum heating for the Apollo flying the same trajectory. TPS designs showed no significant advantage in TPS weight between the different vehicles; however, heat-shield areal density comparisons showed the Apollo configuration to be the most efficient in terms of TPS weight.

Caram, Jose M.↗
NASA NTRS1998

X-33 Base Region Thermal Protection System Design Study

The X-33 is an advanced technology demonstrator for validating critical technologies and systems required for an operational Single-Stage-to-Orbit (SSTO) Reusuable Launch Vehicle (RLV). Currently under development by a unique contractor/government team led by Lockheed- Martin Skunk Works (LMSW), and managed by Marshall Space Flight Center (MSFC), the X-33 will be the prototype of the first new launch system developed by the United States since the advent of the space shuttle. This paper documents a design trade study of the X-33 base region thermal protection system (TPS). Two candidate designs were evaluated for thermal performance and weight. The first candidate was a fully reusable metallic TPS using Inconel honeycomb panels insulated with high temperature fibrous insulation, while the second was an ablator/insulator sprayed on the metallic skin of the vehicle. The TPS configurations and insulation thickness requirements were determined for the predicted main engine plume heating environments and base region entry aerothermal environments. In addition to thermal analysis of the design concepts, sensitivity studies were performed to investigate the effect of variations in key parameters of the base TPS analysis.

Lycans, Randal W.↗
NASA NTRS1999

FTIR Study of Vapor Offgassing from Orbiter Tile Re-Waterproofing Materials

The work presented in this paper was performed to identify and quantify the offgassing behavior of alternative re-waterproofmg materials under investigation for application to Shuttle Orbiter Thermal Protection System (TPS) tile and blanket materials. The purpose was to determine whether the new materials would cause a problem with the operational analysis of residual vapors using the current portable vapor analyzer, a Miran 203. The materials investigated were limited to dimethylethoxysilane (DMES) and proposed solvent selected as suitable for use in re-waterproofing Orbiter TPS. The solvent was selected in another phase of the overall project. Obiter TPS tiles were injected with the re-waterproofing materials under constant conditions of temperature, relative humidity and air flow. The vapor concentrations of offgassing materials were monitored using Fourier Transform Infrared (FTIR) multi-component analysis, and with the Miran 203 instruments. The procedure was to record the time dependent concentrations of offgassing materials as analyzed by the FTIR, and the time response of the Miran 203 to the materials under consideration. The FTIR was calibrated for vapor phase DMES, tetramethyldisiloxane (TMDS), ethanol and the hydrocarbon solvents to be used to dilute the DMES for application to the TPS tile. The Miran 203 was calibrated for the operational measurement of DMES airborne vapors. The FTIR data, shows for the first time that the principal product which offgases from the tile after the first hour is not DMES, but TMDS and ethanol. The Miran 203 response to TMDS is the primary reading after the re-waterproofing operation is completed. The operational use of the Miran 203 to measure DMES vapors after re-waterproofmg operations has been responding to TMDS. The results of this study suggest that the historical complaints that have contributed to the low threshold limit value (TLV) for DMES concentrations, as read with the Miran 203, are actually based on instrumental responses to TMDS, for which no other toxicology information is available at this time. While there is some interference, the use of the tested hydrocarbon solvents does not adversely affect the response of the Miran 203.

Mattson, C. B.↗
NASA NTRS2000

Development of Wireless Subsurface Microsensors for Health Monitoring of Thermal Protection Systems

Low cost access to space is a primary goal for both NASA and the U.S. aerospace industry. Integrated subsystem health diagnostics is an area where major improvements have been identified for potential implementation into the design of new reusable launch vehicles (RLVS) in order to reduce life cycle costs, increase safety margins and improve mission reliability. A number of efforts are underway to use existing and emerging technologies to establish new methods for vehicle health monitoring on operational vehicles as well as X-vehicles. This paper summarizes a joint effort between several NASA centers and industry partners to develop rapid wireless diagnostic tools for failure management and long-term TPS performance monitoring of thermal protection systems (TPS) on future RLVS. An embedded wireless microsensor suite is being designed to allow rapid subsurface TPS health monitoring and damage assessment. This sensor suite will consist of both passive overlimit sensors and sensors for continuous parameter monitoring in flight. The on-board diagnostic system can be used to radio in maintenance requirements before landing and the data could also be used to assist in design validation for X-vehicles. For a 3rd generation vehicle, wireless diagnostics should be at a stage of technical development that will allow use for intelligent feedback systems for guidance and navigation control applications and can also serve as feedback for TPS that can intelligently adapt to its environment.

Pallix, Joan↗
NASA NTRS2002

Metallic Thermal Protection System Technology Development: Concepts, Requirements and Assessment Overview

A technology development program was conducted to evolve an earlier metallic thermal protection system (TPS) panel design, with the goals of: improving operations features, increasing adaptability (ease of attaching to a variety of tank shapes and structural concepts), and reducing weight. The resulting Adaptable Robust Metallic Operable Reusable (ARMOR) TPS system incorporates a high degree of design flexibility (allowing weight and operability to be traded and balanced) and can also be easily integrated with a large variety of tank shapes, airframe structural arrangements and airframe structure/material concepts. An initial attempt has been made to establish a set of performance based TPS design requirements. A set of general (FARtype) requirements have been proposed, focusing on defining categories that must be included for a comprehensive design. Load cases required for TPS design must reflect the full flight envelope, including a comprehensive set of limit loads, However, including additional loads. such as ascent abort trajectories, as ultimate load cases, and on-orbit debris/micro-meteoroid hypervelocity impact, as one of the discrete -source -damage load cases, will have a significant impact on system design and resulting performance, reliability and operability. Although these load cases have not been established, they are of paramount importance for reusable vehicles, and until properly included, all sizing results and assessments of reliability and operability must be considered optimistic at a minimum.

Dorsey, John T.↗
NASA NTRS2001

Evaluation of Advanced Thermal Protection Techniques for Future Reusable Launch Vehicles

A method for integrating Aeroheating analysis into conceptual reusable launch vehicle RLV design is presented in this thesis. This process allows for faster turn-around time to converge a RLV design through the advent of designing an optimized thermal protection system (TPS). It consists of the coupling and automation of four computer software packages: MINIVER, TPSX, TCAT and ADS. MINIVER is an Aeroheating code that produces centerline radiation equilibrium temperatures, convective heating rates, and heat loads over simplified vehicle geometries. These include flat plates and swept cylinders that model wings and leading edges, respectively. TPSX is a NASA Ames material properties database that is available on the World Wide Web. The newly developed Thermal Calculation Analysis Tool (TCAT) uses finite difference methods to carry out a transient in-depth I-D conduction analysis over the center mold line of the vehicle. This is used along with the Automated Design Synthesis (ADS) code to correctly size the vehicle's thermal protection system JPS). The numerical optimizer ADS uses algorithms that solve constrained and unconstrained design problems. The resulting outputs for this process are TPS material types, unit thicknesses, and acreage percentages. TCAT was developed for several purposes. First, it provides a means to calculate the transient in-depth conduction seen by the surface of the TPS material that protects a vehicle during ascent and reentry. Along with the in-depth conduction, radiation from the surface of the material is calculated along with the temperatures at the backface and interior parts of the TPS material. Secondly, TCAT contributes added speed and automation to the overall design process. Another motivation in the development of TCAT is optimization.

Olds, John R.↗
NASA NTRS2001

A Collaborative Analysis Tool for Thermal Protection Systems for Single Stage to Orbit Launch Vehicles

Presented is a design tool and process that connects several disciplines which are needed in the complex and integrated design of high performance reusable single stage to orbit (SSTO) vehicles. Every system is linked to all other systems, as is the case with SSTO vehicles with air breathing propulsion, which is currently being studied by the National Aeronautics and Space Administration (NASA). In particular, the thermal protection system (TPS) is linked directly to almost every major system. The propulsion system pushes the vehicle to velocities on the order of 15 times the speed of sound in the atmosphere before pulling up to go to orbit which results in high temperatures on the external surfaces of the vehicle. Thermal protection systems to maintain the structural integrity of the vehicle must be able to mitigate the heat transfer to the structure and be lightweight. Herein lies the interdependency, in that as the vehicle's speed increases, the TPS requirements are increased. And as TPS masses increase the effect on the propulsion system and all other systems is compounded. To adequately calculate the TPS mass of this type of vehicle several engineering disciplines and analytical tools must be used preferably in an environment that data is easily transferred and multiple iterations are easily facilitated.

Alexander, Reginald↗
NASA NTRS1997

Automotive Insulation

Under a Space Act Agreement between Boeing North America and BSR Products, Space Shuttle Thermal Protection System (TPS) materials are now used to insulate race cars. BSR has created special TPS blanket insulation kits for use on autos that take part in NASCAR events, and other race cars through its nationwide catalog distribution system. Temperatures inside a race car's cockpit can soar to a sweltering 140 to 160 degrees, with the extreme heat coming through the engine firewall, transmission tunnel, and floor. It is common for NASCAR drivers to endure blisters and burns due to the excessive heat. Tests on a car insulated with the TPS material showed a temperature drop of some 50 degrees in the driver's cockpit. BSR-TPS Products, Inc. now manufactures insulation kits for distribution to race car teams around the world.

Source record↗
NASA NTRS2002

Thermal Protection System Evaluation Using Arc-jet Flows: Flight Simulation or Research Tool?

The arc-jet has been used to evaluate thermal protection systems (TPS) and materials for the past forty years. Systems that have been studied in this environmerd include ablators, active, and passive TPS concepts designed for vehicles entering planetary and Earth atmospheres. The question of whether arc-jet flow can simulate a flight environment or is it a research tool that provides an aero-thermodynamic heating environment to obtain critical material properties will be addressed. Stagnation point tests in arc-jets are commonly used to obtain material properties such as mass loss rates, thermal chemical stability data, optical properties, and surface catalytic efficiency. These properties are required in computational fluid dynamic codes to accurately predict the performance of a TPS during flight. Special facilities have been developed at NASA Ames Research Center to approximate the flow environment over the mid-fuselage and body flap regions of proposed space-planes type vehicles. This paper compares flow environments generated in flight over a vehicle with those created over an arc-jet test articles in terms of scale, chemistry, and fluid dynamic properties. Flight experiments are essential in order to validate the material properties obtained from arc-jet tests and used to predict flight performance of any TPS being considered for use on a vehicle entering the Earth atmosphere at hypersonic speed.

Stewart, David A.↗
NASA NTRS2004

Aeroheating Design Issues for Reusable Launch Vehicles: A Perspective

An overview of basic aeroheating design issues for Reusable Launch Vehicles (RLV), which addresses the application of hypersonic ground-based testing, and computational fluid dynamic (CFD) and engineering codes, is presented. Challenges inherent to the prediction of aeroheating environments required for the successful design of the RLV Thermal Protection System (TPS) are discussed in conjunction with the importance of employing appropriate experimental/computational tools. The impact of the information garnered by using these tools in the resulting analyses, ultimately enhancing the RLV TPS design is illustrated. A wide range of topics is presented in this overview; e.g. the impact of flow physics issues such as boundary-layer transition, including effects of distributed and discrete roughness, shockshock interactions, and flow separation/reattachment. Also, the benefit of integrating experimental and computational studies to gain an improved understanding of flow phenomena is illustrated. From computational studies, the effect of low-density conditions and of uncertainties in material surface properties on the computed heating rates are highlighted as well as the significant role of CFD in improving the Outer Mold Line (OML) definition to reduce aeroheating while maintaining aerodynamic performance. Appropriate selection of the TPS design trajectories and trajectory shaping to mitigate aeroheating levels and loads are discussed. Lastly, an illustration of an aeroheating design process is presented whereby data from hypersonic wind-tunnel tests are integrated with predictions from CFD codes and engineering methods to provide heating environments along an entry trajectory as required for TPS design.

Zoby, E. Vincent↗
NASA NTRS2004

Aeroheating Design Issues for Reusable Launch Vehicles: A Perspective

An overview of basic aeroheating design issues for Reusable Launch Vehicles (RLV), which addresses the application of hypersonic ground-based testing, and computational fluid dynamic (CFD) and engineering codes, is presented. Challenges inherent to the prediction of aeroheating environments required for the successful design of the RLV Thermal Protection System (TPS) are discussed in conjunction with the importance of employing appropriate experimental/computational tools. The impact of the information garnered by using these tools in the resulting analyses, ultimately enhancing the RLV TPS design is illustrated. A wide range of topics is presented in this overview; e.g. the impact of flow physics issues such as boundary-layer transition, including effects of distributed and discrete roughness, shock-shock interactions, and flow separation/reattachment. Also, the benefit of integrating experimental and computational studies to gain an improved understanding of flow phenomena is illustrated. From computational studies, the effect of low-density conditions and of uncertainties in material surface properties on the computed heating rates a r e highlighted as well as the significant role of CFD in improving the Outer Mold Line (OML) definition to reduce aeroheating while maintaining aerodynamic performance. Appropriate selection of the TPS design trajectories and trajectory shaping to mitigate aeroheating levels and loads are discussed. Lastly, an illustration of an aeroheating design process is presented whereby data from hypersonic wind-tunnel tests are integrated with predictions from CFD codes and engineering methods to provide heating environments along an entry trajectory as required for TPS design.

Zoby, E. Vincent↗
NASA NTRS2007

Development of Natural Flaw Samples for Evaluating Nondestructive Testing Methods for Foam Thermal Protection Systems

Low density polyurethane foam has been an important insulation material for space launch vehicles for several decades. The potential for damage from foam breaking away from the NASA External Tank was not realized until the foam impacts on the Columbia Orbiter vehicle caused damage to its Leading Edge thermal protection systems (TPS). Development of improved inspection techniques on the foam TPS is necessary to prevent similar occurrences in the future. Foamed panels with drilled holes for volumetric flaws and Teflon inserts to simulate debonded conditions have been used to evaluate and calibrate nondestructive testing (NDT) methods. Unfortunately the symmetric edges and dissimilar materials used in the preparation of these simulated flaws provide an artificially large signal while very little signal is generated from the actual defects themselves. In other words, the same signal are not generated from the artificial defects in the foam test panels as produced when inspecting natural defect in the ET foam TPS. A project to create more realistic voids similar to what actually occurs during manufacturing operations was began in order to improve detection of critical voids during inspections. This presentation describes approaches taken to create more natural voids in foam TPS in order to provide a more realistic evaluation of what the NDT methods can detect. These flaw creation techniques were developed with both sprayed foam and poured foam used for insulation on the External Tank. Test panels with simulated defects have been used to evaluate NDT methods for the inspection of the External Tank. A comparison of images between natural flaws and machined flaws generated from backscatter x-ray radiography, x-ray laminography, terahertz imaging and millimeter wave imaging show significant differences in identifying defect regions.

Workman, Gary L.↗