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At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

History and State of the Art in Advanced Thermal Protection Systems

This report documents the current state of the art of thermal protection systems (TPS) relevant to missile application materials and MTCR control language. The information is intended to provide data on current TPS for determining the current state of development and identifying potential research directions. Various vehicle configurations and types of TPS are described, including the evolution of materials and systems. Vehicle configurations such as high drag rocket and capsule systems and low-drag air-breathers are discussed. TPS are complex, transitioning from often very low temperatures to temperatures exceeding 3000°C and heat fluxes of up to 30,000 W/cm 2 . They can take the form of blankets, sheets, tiles and fabricated rigid structures, and can be made from high temperature capable alloys, refractory metals, ceramics, ceramic matrix composites, ultra-high temperature ceramics, carbon-carbon composites or ablative carbonaceous materials. Current state of the art in TPS is based on materials any systems developed for the initial space program. TPS was upgraded to the point of the Space Shuttle development and has stagnated since them.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Advanced Manufacturing of Thermal Protection System Tiles for Space Plane Atmospheric Reentry

Thermal protection systems (TPS) constitute a major material, engineering, and manufacturing challenge for space access. Atmospheric re-entry generates very high heats and requires advanced materials to withstand such conditions. Combining the required materials and integrating them into the vehicle is a major engineering undertaking that often must use creative designs to accommodate the selected materials and systems. Likewise, the manufacture of TPS is costly and challenging; it requires a combination of materials in a range of complex and unique shapes with specialized process conditions. Compounding these challenges, for harsh re-entry profiles or on high heat flux regions of the vehicle, even state of the art TPS is effectively single use and thereby creating a strong economic incentive to improve the TPS materials, integration, and manufacture. This work focuses on the use of ceramic modifications to TPS materials thereby allowing multi flight capability.

36 MATERIALS SCIENCE↗
NASA NTRS1971

Preliminary vibration design and test criteria considerations for the space shuttle

This paper presents some Marshall Space Flight Center preliminary vibration design and test criteria considerations for the space shuttle. The discussion is primarily concerned with the formulation of vibration criteria for the design and testing of the equipment installations on the shuttle. A recommended criteria format is presented with a discussion of when the vibration environment has to be considered in design and testing. A semiempirical method of predicting the vibration criteria for the shuttle from vibroacoustic structural data banks is presented. Some preliminary vibration criteria predictions are presented for the orbiter and booster equipment bays and for the main shuttle engine. A research testing program to determine the vibroacoustic transfer through a typical shuttle thermal protection system (TPS) panel configuration is described.

Harry J. Bandgren↗
NASA NTRS1972

Refurbishment cost study of the thermal protection system of a space shuttle vehicle, phase 2

The labor costs and techniques associated with the refurbishment and maintenance of representative thermal protection system (TPS) components and their attachment concepts suitable for space shuttle application are defined, characterized, and evaluated from the results of an experimental test program. This program consisted of designing selected TPS concepts, fabricating and assembling test hardware, and performing a time and motion study of specific maintenance functions of the test hardware on a full-scale- mockup. Labor requirements and refurbishment techniques, as they relate to the maintenance functions of inspection, repair, removal, and replacement were identified.

Haas, D. W.↗
NASA NTRS1972

Determination of aerothermodynamic environment uncertainties with application to space shuttle vehicles

In an effort to minimize the cost of the thermal protection system (TPS) for space shuttles, an analysis is made of environmental uncertainties. The basic categories of these uncertainties include aerodynamic heating, trajectory dispersions, atmospheric variations, and vehicle attitude variations. Also discussed are TPS design sensitivity to environmental uncertainties, and uncertainty profiles. Preliminary results indicate moderate TPS cost for a high confidence level environment may be obtained.

Scottoline, C. A.↗
NASA NTRS1972

Refurbishment cost study of the thermal protection system of a space shuttle vehicle. Phase 2: Supplement

The labor costs and techniques associated with the maintenance of a bonded-on ablator thermal protection system (TPS) concept, suitable for Space Shuttle application are examined. The baseline approach to TPS attachment involves bonding reusable surface insulation (RSI) and/or ablators to the structural skin of the vehicle. The RSI and/or ablators in the form of either flat or contoured panels can be bonded to the skin of the primary structure directly or by way of an intermediate silicone foam rubber pad. The use of foam rubber pads permits the use of buckling skins and protruding heat rivets on the primary structure, minimizing structural weight and fabrication costs. In the case of the RSI, the foam rubber pad serves as a required strain isolator. For purpose of comparison, test data were obtained for an installation with and without the use of a strain isolator. The refurbishment aspects of a bonded-on RSI concept (without a strain isolator) were examined experimentally along with several externally removable panel concepts employing both ablator and RSI TPS. The various concepts are compared.

Haas, D. W.↗
NASA NTRS1972

Optimization of thermal protection systems for the space vehicle. Volume 2: User's manual

The development of the computational techniques for the design optimization of thermal protection systems for the space shuttle vehicle are discussed. The resulting computer program was then used to perform initial optimization and sensitivity studies on a typical thermal protection system (TPS) to demonstrate its application to the space shuttle TPS design. The program was developed in FORTRAN IV for CDC 6400 computer, but it was subsequently converted to the FORTRAN V language to be used on the Univac 1108.

Source record↗
NASA NTRS1973

Coated columbium thermal protection systems: An assessment of technological readiness

Evaluation and development to date show that of the coated columbium alloys FS-85 coated with R512E shows significant promise for a reusable thermal protection system (TPS) as judged by environmental resistance and the retention of mechanical properties and structural integrity of panels upon repeated reentry simulation. Production of the alloy, the coating, and full-sized TPS panels is well within current manufacturing technology. Small defects which arise from impact damage or from local coating breakdown do not appear to have serious immediate consequences in the use environment anticipated for the space shuttle orbiter TPS.

Levine, S. R.↗
NASA NTRS1972

Study of Uncertainties of Predicting Space Shuttle Thermal Environment

Quantitative estimates of the uncertainty in predicting aerodynamic heating rates for a fully reusable space shuttle system are developed and the impact of these uncertainties on Thermal Protection System (TPS) weight are discussed. The study approach consisted of statistical evaluations of the scatter of heating data on shuttle configurations about state-of-the-art heating prediction methods to define the uncertainty in these heating predictions. The uncertainties were then applied as heating rate increments to the nominal predicted heating rate to define the uncertainty in TPS weight. Separate evaluations were made for the booster and orbiter, for trajectories which included boost through reentry and touchdown. For purposes of analysis, the vehicle configuration is divided into areas in which a given prediction method is expected to apply, and separate uncertainty factors and corresponding uncertainty in TPS weight derived for each area.

Fehrman, A. L.↗
NASA NTRS1974

Data correlation and analysis of arc tunnel and wind tunnel tests of RSI joints and gaps. Volume 2: Data base

Wind tunnel tests were conducted to determine the aerodynamic heating created by gaps in the reusable surface insulation (RSI) thermal protection system (TPS) for the space shuttle. The effects of various parameters of the RSI on convective heating characteristics are described. The wind tunnel tests provided a data base for accurate assessment of gap heating. Analysis and correlation of the data provide methods for predicting heating in the RSI gaps on the space shuttle.

Christensen, H. E.↗
NASA NTRS1974

Feasibility and tradeoff study of an aeromaneuvering orbit-to-orbit shuttle (AMOOS)

This study establishes that configurations satisfying the aeromaneuvering orbit-to-orbit shuttle (AMOOS) requirements can be designed with performance capabilities in excess of the purely propulsive space tug. In view of this improved potential of the AMOOS vehicle over the propulsive space tug concept it is recommended that the AMOOS studies be advanced to a stage comparable to those performed for the space tug. This advancement is needed in particular in areas that are either peculiar to AMOOS or not addressed in sufficient detail in these studies to date. These areas include the thermodynamics problems, navigation and guidance, operations and economics analyses, subsystems and interfaces. The aeromaneuvering orbit-to-orbit shuttle (AMOOS) is evaluated as a candidate reusable third stage to the two-stage earth-to-orbit shuttle (EOS). AMOOS has the potential for increased payload capability over the purely propulsive space tug by trading a savings in consumables for an increase in structural and thermal protection system (TPS) mass.

White, J.↗
NASA NTRS1974

Thermal-Structural Evaluation of TD Ni-20Cr Thermal Protection System Panels

The results of a thermal-structural test program to verify the performance of a metallic/radiative Thermal Protection System (TPS) under reentry conditions are presented. This TPS panel is suitable for multiple reentry, high L/D space vehicles, such as the NASA space shuttle, having surface temperatures up to 1200 C (2200 F). The TPS panel tested consists of a corrugation-stiffened, beaded-skin TD Ni-20Cr metallic heat shield backed by a flexible fibrous quartz and radiative shield insulative system. Test conditions simulated the critical heating and aerodynamic pressure environments expected during 100 repeated missions of a reentry vehicle. Temperatures were measured during each reentry cycle; heat-shield flatness surveys to measure permanent set of the metallic components were made every 10 cycles. The TPS panel, in spite of localized surface failures, performed its designated function.

Eidinoff, H. L.↗
NASA NTRS1973

Thermoacoustic fatigue testing facility for space shuttle thermal protection system

The development of a reusable space shuttle by NASA in the next decade depends in part on the design of a satisfactory thermal protection system (TPS). The booster and orbiter parts of the shuttle require TPS panels which will withstand thermoacoustic fatigue. The Langley Research Center has begun tests on early panel designs in a new acoustic fatigue facility which is capable of simulating the combined elevated temperature and acoustic environments which these panels are expected to experience. The capabilities of the facility and computer system are outlined, and problems encountered in establishing the test methods are discussed. Tests of a Haynes 25 TPS panel are described, and representative data from tests of the panel at 650 C are included.

Rucker, C. E.↗
NASA NTRS1975

Fail-safe system for activity cooled supersonic and hypersonic aircraft

A fail-safe-system concept was studied as an alternative to a redundant active cooling system for supersonic and hypersonic aircraft which use the heat sink of liquid-hydrogen fuel for cooling the aircraft structure. This concept consists of an abort maneuver by the aircraft and a passive thermal protection system (TPS) for the aircraft skin. The abort manuever provides a low-heat-load descent from normal cruise speed to a lower speed at which cooling is unnecessary, and the passive TPS allows the aircraft skin to absorb the abort heat load without exceeding critical skin temperature. On the basis of results obtained, it appears that this fail-safe-system concept warrants further consideration, inasmuch as a fail-safe system could possibly replace a redundant active cooling system with no increase in weight and would offer other potential advantages.

Jones, R. A.↗
NASA NTRS1975

Data correlation and analysis of arc tunnel and wind tunnel tests of RSI joints and gaps, phase 2. Volume 1: Technical report

Heat transfer data measured in gaps representative of those being employed for joints in the space shuttle reusable surface insulation (RSI) thermal protection systems (TPS) were assimilated, analyzed, and correlated. Several types of gap were investigated with emphasis on simple butt joints. Gap widths ranged from 0.0 to 0.76 cm and depths ranged from 1 to 6 cm. Laminar, transitional, and turbulent boundary layer flows over the gap opening were investigated. The angle between gap axis and external flow was varied between 0 and pi/2 radians. The contoured cross section gap performed significantly better than all other wide gaps and slightly better than all other narrow gap geometries. Three dimensional heating variations were observed within gaps in the absence of external flow pressure gradients. Interactions between heating within gaps and heating of adjacent top tile surfaces were observed. Gaps aligned with the flow were observed to promote boundary layer transition. Heat transfer correlation equations were obtained for many of the tests. The TPS thickness requirements with and without gaps were computed for a current shuttle entry trajectory. Experimental data employed in the study are summarized. A description of each test facility, run schedule and test conditions, model descriptive information, and heat flux data are included.

Cristensen, H. E.↗
NASA NTRS1975

An experimental summary of plasma arc exposures of space shuttle high-temperature reusable surface insulation tile array with a single missing tile (conducted at the Ames Research Center)

A space shuttle high temperature reusable surface insulation (HRSI) tile array with a single missing or lost tile was exposed to a hot gas simulated reentry environment to investigate the heating conditions in and around the vicinity of the missing HRSI tile. Heat flux and pressure data for the lost tile condition were obtained by the use of a water cooled lost tile calibration model. The maximum aluminum substrate temperature obtained during the simulated reentry was 128 C (263 F). The lost tile calibration data indicated a maximum heat flux in the lost tile cavity region of 63 percent of the upstream reference value. This test was conducted at the Ames Research Center in the 20 MW semielliptical thermal protection system (TPS) pilot plasma arc test facility.

Galanter, S. A.↗
NASA NTRS1974

Simulated lightning test shuttle .03 scale model

Lightning Attach Point tests were conducted for the space shuttle launch configuration (Orbiter, External Tank and Solid Rocket Boosters). A series of 250 long spark tests (15 to 20 foot sparks) determined that the orbiter may be struck on the nose, windshield brow, tail and wingtips during launch but not on the main engine nozzles which have been shown to be vulnerable to lightning damage. The orbiter main engine and SRB exhaust plumes were simulated electrically with physical models coated with graded resistance paints. The tests showed that the exhaust plumes from the SRB provide additional protection for the main engine nozzles. However, the tests showed that the Orbiter Thermal Protection System (TPS), which has also been shown to be vulnerable to lightning damage, may be struck during launch. Therefore further work is indicated in the areas of swept stroke studies on the model and on TPS panels. Further attach point testing is also indicated on the free-flying orbiter. Photographs of the test setup are shown.

Clifford, D. W.↗