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NASA NTRS2017

Modeling the Relationship Between Porosity and Permeability During Oxidation of Ablative Materials

The ablative materials used in thermal protection systems (TPS) undergo oxidation during atmospheric entry which leads to an in-depth change in both permeability and porosity. These properties have a significant affect on heat transfer in a TPS during entry. X-ray micro-tomography has provided 3D images capturing the micro-structure of TPS materials. In this study, we use micro-tomography based simulations to create high-fidelity models relating permeability to porosity during oxidation of FiberForm, the carbon fiber preform of the Phenolic Impregnated Carbon Ablator (PICA) often used as a TPS material. The goal of this study is to inform full-scale models and reduce uncertainty in TPS modeling.

Ablativ↗

NASA NTRSDate not supplied

Bridging the Gap Between Microscale Modeling and Additive Manufacturing for TPS

An overview of the now open-source NASA ARC software PuMA will be provided. On top of the well-documented ability to import and compute material properties from micro-CT images, PuMA has the ability to design microstructures and compute/predict material properties such as: porosity, permeability, tortuosity, thermal and electrical conductivity, tensile strength, etc. Therefore, a whole new range of capabilities is available, and provides users with the ability to build TPS materials (both fibrous and woven types) and optimize their properties based on missions and requirements. This talk will aim to provide a seed to start bridging the gap between microscale modeling of TPS materials and additive manufacturing.

Conductivity↗

NASA NTRS2017

Verification of a Finite Element Model for Pyrolyzing Ablative Materials

Ablating thermal protection system (TPS) materials have been used in many reentering spacecraft and in other applications such as rocket nozzle linings, fire protection materials, and as countermeasures for directed energy weapons. The introduction of the finite element model to the analysis of ablation has arguably resulted in improved computational capabilities due the flexibility and extended applicability of the method, especially to complex geometries. Commercial finite element codes often provide enhanced capability compared to custom, specially written programs based on versatility, usability, pre- and post-processing, grid generation, total life-cycle costs, and speed.

ablating materials↗

NASA NTRS2011

Ablator Modeling: Why Not Much Has Changed Over the Past 45 plus Years

In the late 1950s, the earliest models describing the thermal response of ablative materials were based on the heat of ablation concept, which is an empirical approach that was reasonable for the types of materials of interest at that time. In the early-mid 60s the models were expanded to include pyrolysis since organic resin composites became the TPS materials of interest. However, surface recession was still predominantly modeled via empirical correlation. The development of the 1-D CMA finite difference code in the mid-late 60s introduced the thermochemical ablation approach for gas/surface interactions. Since that time investigators have developed finite volume and finite element codes, in 1-D, 2-D and 3-D, but the basic modeling has not evolved significantly. Models describing internal gas pressure due to pyrolysis, particle impact erosion, in-depth radiant transport, etc., have been added to address specific problems, but the fundamental modeling has not evolved. The reasons for this stagnation, as viewed by the author, will be described.

Laub, B.↗

NASA NTRS2001

Thermal Analysis of the MC-1 Chamber/Nozzle

This paper will describe the thermal analysis techniques used to predict temperatures in the film-cooled ablative rocket nozzle used on the MC-1 60K rocket engine. A model was developed that predicts char and pyrolysis depths, liner thermal gradients, and temperatures of the bondline between the overwrap and liner. Correlation of the model was accomplished by thermal analog tests performed at Southern Research, and specially instrumented hot fire tests at the Marshall Space Flight Center. Infrared thermography was instrumental in defining nozzle hot wall surface temperatures. In-depth and outboard thermocouple data was used to correlate the kinetic decomposition routine used to predict char and pyrolysis depths. These depths were anchored with measured char and pyrolysis depths from cross-sectioned hot-fire nozzles. For the X-34 flight analysis, the model includes the ablative Thermal Protection System (TPS) material that protects the overwrap from the recirculating plume. Results from model correlation, hot-fire testing, and flight predictions will be discussed.

Davis, Darrell W.↗

NASA NTRS2001

Thermal Analysis of the Fastrac Chamber/Nozzle

This paper will describe the thermal analysis techniques used to predict temperatures in the film-cooled ablative rocket nozzle used on the Fastrac 60K rocket engine. A model was developed that predicts char and pyrolysis depths, liner thermal gradients, and temperatures of the bondline between the overwrap and liner. Correlation of the model was accomplished by thermal analog tests performed at Southern Research, and specially instrumented hot fire tests at the Marshall Space Flight Center. Infrared thermography was instrumental in defining nozzle hot wall surface temperatures. In-depth and outboard thermocouple data was used to correlate the kinetic decomposition routine used to predict char and pyrolysis depths. These depths were anchored with measured char and pyrolysis depths from cross-sectioned hot-fire nozzles. For the X-34 flight analysis, the model includes the ablative Thermal Protection System (TPS) material that protects the overwrap from the recirculating plume. Results from model correlation, hot-fire testing, and flight predictions will be discussed.

Davis, Darrell↗

NASA NTRSDate not supplied

TPS Certification by Analysis: Model-Driven Characterization of Properties and Failure in Woven Thermal Protection Systems

Woven, ablative thermal protection system (TPS) materials provide a robust option for aggressive (re)entries and thus have been baselined for the upcoming Mars Sample Return (MSR) mission's Earth Entry System (EES). The reliability requirements for MSR-EES necessitate understanding of material property variability, which could be significant given the complex structure and anisotropic nature of properties in TPS weaves, as well as the response to potential impact with micrometeoroids or orbital debris during the EES re-entry. The TPS Certification by Analysis effort within the Entry Systems Modeling project seeks to provide computational models and analyses that support the certification against such material-based risks. For the present talk, focus will be given to the characterization of baseline woven TPS material properties and mechanical failure limits, which entails (1) use of computational techniques (e.g., machine learning) to interpret computed tomography images of the weave to generate representative structural models and (2) application of multiscale material modeling approaches to characterize thermomechanical and failure properties.

thermal protection systems↗

NASA NTRSDate not supplied

TPS Certification by Analysis: Model-Driven Characterization of Properties and Failure in Woven Thermal Protection Systems

Woven, ablative thermal protection system (TPS) materials provide a robust option for aggressive (re)entries and thus have been baselined for the upcoming Mars Sample Return (MSR) mission’s Earth Entry System (EES). The reliability requirements for MSR-EES necessitate understanding of material property variability, which could be significant given the complex structure and anisotropic nature of properties in TPS weaves, as well as the response to potential impact with micrometeoroids or orbital debris during the EES re-entry. The TPS Certification by Analysis effort within the Entry Systems Modeling project seeks to provide computational models and analyses that support the certification against such material-based risks. For the present talk, focus will be given to the characterization of baseline woven TPS material properties and mechanical failure limits, which entails (1) use of computational techniques (e.g., machine learning) to interpret computed tomography images of the weave to generate representative structural models and (2) application of multiscale material modeling approaches to characterize thermomechanical and failure properties.

Justin B. Haskins↗

NASA NTRS2015

Aerothermal Considerations for Entry, Descent, and Landing

Aerothermal modeling is inherently entwined with TPS design. Aerothermal, radiation, and TPS material response are coupled so it's important to check modeling assumptions. Validation of numerical models using ground and flight tests is important to quantify uncertainties. A margin policy based on statistical methods may provide greater insight in the key drivers and overall reliability of the design

Tang, Chun↗

NASA NTRSDate not supplied

Material Response Modeling of Ablative Thermal Protection Systems using PATO

Developing thermal protection systems (TPS) for future space vehicles involves an extensive design and test cycle. A key component of the cycle is determining margins for a safe design that rely on confidence in the performance of the TPS. Predicting the complicated multiphysics phenomena that occur during atmospheric entry requires high-fidelity modeling tools. To this end, the Porous-material Analysis Toolbox based on OpenFOAM (PATO) has been developed. PATO is an open-source software for computing material response of reactive porous materials submitted to high-temperature environments. Recent applications of PATO include computation of the full heatshield 3D material response from the Mars Science Laboratory atmospheric entry and ablation during arc jet testing. Current efforts are underway to loosely couple PATO with other discipline specialized codes including hypersonic computational fluid dynamics (CFD) to assess the effects of pyrolysis-gas blowing into the boundary layer and computational solid mechanics to address modeling of mechanical erosion. Surface phenomena modeling capabilities to address the effects of silicone-based coatings applied to the TPS during flight preparation are also being added.

Thermal Protection Systems↗

NASA NTRSDate not supplied

Material Response Modeling of Ablative Thermal Protection Systems using PATO

Thermal Protection Systems↗

NASA NTRSDate not supplied

Advances in Design Capabilities for Planetary Missions from the NASA Entry Systems Modeling and Instrumentation Portfolio

The Entry Systems Modeling project (ESM) is supported by both the NASA Space Technology and the Science Mission Directorates and focuses on developing simulation tools and validated models for characterizing the performance of entry systems tailored to planetary destinations across the Solar System. ESM is organized into six technical capability areas that together address all relevant factors related to spacecraft entry, as well as some aspects of descent: Thermal Protection System (TPS) Materials; Aerothermodynamics; Entry & Descent Vehicle Dynamics; Guidance, Navigation, and Control; Vehicle Systems Analysis; and Advanced Tools and Numerical Methods. Development within the capability areas is undertaken explicitly with a focus on transition and infusion to science missions, human exploration missions, and commercial space activities. The present talk details developments that specifically impact science missions, including simulation tool capabilities that aid in mission design and model development to understand entry system performance at a given destination. Examples of the successful infusion and transition of such project outcomes to science missions also are provided. Several simulation tool development efforts within ESM have resulted in new design capabilities for missions. One such outcome is improved toolsets for mission trajectory and concept of operations design. Specifically, an initiative to couple a leading tool for entry, ascent/descent, and orbital trajectory optimization (Program to Optimize Simulated Trajectories II or POST2) to those used within the Agency for interplanetary trajectory optimization (Copernicus and Monte) has made substantial progress, with the outcomes to date promising to allow efficient trajectory optimization across mission phases. Additionally, toolchains for the evaluation of vehicle performance during entry and descent have been developed that allow assessment of multi-dimensional aeroheating on detailed vehicle geometries, characterization of deployment and inflation of parachutes, and assessment of vehicle dynamic stability during descent. These capabilities are achieved by coupling diverse sets of physics together – material response, computational fluid dynamics, radiation, and vehicle dynamics – to suitably describe complex entry and descent phenomena. Several model development and validation efforts for specific destinations and entry regimes also are underway within the ESM project. For instance, new experimental capabilities to validate radiation models at low densities/high altitudes recently have been established with project support, specifically the Low-Density Shock Tube (LDST) at the NASA Ames Research Center Electric Arc Shock Tube (EAST) facility. The LDST is being leveraged to develop improved models of shock layer kinetics and radiation in Titan atmospheres, while future studies will be conducted in the LDST and the existing high velocity shock tube to provide validation data for radiation models of Venus, Ice Giants, and Mars atmospheres. Models describing the aerothermal and thermo-structural performance of Thermal Protection System (TPS) materials has been another focus, with multiscale modeling activities on-going for the two leading TPS materials applicable to a range of entry conditions and science missions: the Phenolic-Impregnated Carbon Ablator (PICA) and woven materials like 3D Mid-Density Carbon Phenolic (3MDCP). A continual effort is made to infuse and transition outcomes from ESM simulation tool and model development activities into relevant science missions. Significant progress has been made on this front, with missions such as Dragonfly, DAVINCI, and Mars Missions benefitting from project outcomes. The groundwork also is being laid to provide insights into forward looking missions to Gas/Ice Giants as well as for potential sample returns.

Justin Haskins↗

NASA NTRSDate not supplied

MEDLI2: Ablator Models for Flight

During the entry of Mars Science Laboratory (MSL) the heatshield was equipped with the instrumentation suite Mars Entry, Descent, and Landing Instruments (MEDLI). In-depth thermocouple (TC) data was used to reconstruct the surface heating[1,2]. Discrepancies between MEDLI’s flight heating data and predicted thermal response and recession[3] led to a campaign to characterize and test Mars2020 and MEDLI2 (Mars Entry, Descent, and Landing Instrument 2)[4] flight-lot thermal protection materials (TPS) at relevant ground test conditions. This paper covers the development and validation of flight-lot material response models for the heatshield material Phenolic Impregnated Carbon Ablator (PICA) and the backshell material SLA-561V (Super Lightweight Ablator). Virgin and char properties such as thermal conductivity and emissivity were updated as a function of temperature and pressure in the MEDLI2 specific material response models. Other material properties were characterized and determined to be similar to prior TPS material measurements used for the heritage models. MEDLI2 also investigated the impact of the protective coating that was applied to MSL and Mars2020’s PICA heatshield to reduce the particulate matter shedding. Evidence from arc jet experiments on coated PICA showed that although there were no adverse effects on the performance of the TPS, there were differences in the in-depth temperatures and reduced recession compared to material response predictions of uncoated PICA.[5,6]. Fully Implicit Ablation and Thermal response (FIAT)[7] material response simulations were conducted with the heritage and MEDLI2 flight-lot material models. FIAT-predicted in-depth temperature responses and recession predictions were compared to flight-lot certification ground-test arc jet test data and MEDLI2 thermocouple data.

Materials Response↗

NASA NTRS1989

Thermal Protection System of the Space Shuttle

The Thermal Protection System (TPS), introduced by NASA, continues to incorporate many of the advances in materials over the past two decades. A comprehensive, single-volume summary of the TPS, including system design rationales, key design features, and broad descriptions of the subsystems of TPS (E.g., reusable surface insulation, leading edge structural, and penetration subsystems) is provided. Details of all elements of TPS development and application are covered (materials properties, manufacturing, modeling, testing, installation, and inspection). Disclosures and inventions are listed and potential commercial application of TPS-related technology is discussed.

Cleland, John↗

NASA NTRS2017

From Tomography to Material Properties of Thermal Protection Systems

A NASA Ames Research Center (ARC) effort, under the Entry Systems Modeling (ESM) project, aims at developing micro-tomography (micro-CT) experiments and simulations for studying materials used in hypersonic entry systems. X-ray micro-tomography allows for non-destructive 3D imaging of a materials micro-structure at the sub-micron scale, providing fiber-scale representations of porous thermal protection systems (TPS) materials. The technique has also allowed for In-situ experiments that can resolve response phenomena under realistic environmental conditions such as high temperature, mechanical loads, and oxidizing atmospheres. Simulation tools have been developed at the NASA Ames Research Center to determine material properties and material response from the high-fidelity tomographic representations of the porous materials with the goal of informing macroscopic TPS response models and guiding future TPS design.

Tomography↗

NASA NTRS2019

Laboratory-Based Thermal Shock Investigation of Heat Flux Sensors for the Mars 2020 Backshell

In 2012 during the entry, descent, and landing of the Mars Science Laboratory (MSL), the MSL Entry, Descent, and Landing Instrumentation (MEDLI) sensor suite was collecting in-flight heatshield pressure and temperature data. The data collected by the MEDLI instruments has since been used for reconstruction of vehicle aerodynamics, atmospheric conditions, aerothermal heating, and Thermal Protection System (TPS) performance as well as material response model validation and refinement. The Mars Entry, Descent, and Landing Instrumentation 2 (MEDLI2) sensor suite for the Mars 2020 heatshield and backshell is being designed to expand on the measurements and knowledge gained from MEDLI. Similar to MEDLI, MEDLI2 will measure the pressure and temperature of the heatshield. MEDLI2 will additionally measure the temperature, pressure, total heat flux, and radiative heat flux on the backshell.Since the backshell instrumentation is new to MEDLI2, Do No Harm (DNH) testing was conducted on instrumented backshell TPS (SLA-561V) panels. The panels consisted of four pressure port holes, one Mars Entry Atmospheric Data System (MEADS) pressure port plug, one MEDLI2 Integrated Sensor Plug (MISP) thermal plug, and one heat flux sensor. DNH testing was conducted to ensure the performance of the TPS was not degraded due to sensor integration and to characterize any TPS performance changes. The testing consisted of environmental testingâ€” vibration, shock, thermal vacuum (TVAC) cyclingâ€” and bounding aerothermal (arc jet) testing. During arc jet testing, the heat flux sensors embedded in the SLA-561V panels exhibited an unexpected temporary reduction in the heat flux sensor temperature and response. After review of the test results, it was determined that this unexpected response was confined to the two heat flux sensors that experienced the greatest thermal shock condition. This condition consisted of a liquid nitrogen (LN2) bath that induced temperatures of approximately -190Â°C, and then a transition (thermal shock) to an arc jet test at a heat rate of approximately 21 W/cm2. Both heat flux sensors that were exposed to this thermal shock experienced a blister in the thermal coating during the arc jet test.Two heat flux sensor thermal shock test series were performed to investigate the cause of the blistering and subsequent energy release. In these tests, the heat flux sensor was first cold soaked in either a dry ice or LN2 bath to induce temperatures of approximately -78Â°C or -190Â°C, respectively. Then the sensors were thermally shocked using two propane torches with a heat rate of either approximately 8 W/cm2 or 21 W/cm2. The key findings indicated that there is a correlation between thermal shock and the blistering observed in the DNH test series, and that the cause appeared to be rooted in the heat flux sensor epoxy that encapsulates the sensor thermopile.Since the heat flux sensors are required to measure heat fluxes up to 15 W/cm2 during the Mars 2020 entry, a third test series was designed to determine if blistering is an issue at this maximum expected flight heat flux. Results from all three thermal shock test series and a discussion about whether or not blistering of the heat flux sensor thermal coating could be an issue for the Mars 2020 mission will be presented.

Miller, R. A.↗

NASA NTRS2019

Laboratory-Based Thermal Shock Investigation of Heat Flux Sensors for the Mars 2020 Backshell

Miller, R. A.↗

NASA NTRSDate not supplied

Multiscale Thermal Conductivity Modeling of 3D Woven Composite Thermal Protection System Materials

Novel thermal protection systems (TPS) for re-entry and hypersonic vehicles utilize 3D woven composite materials with blended carbon filament tows (yarns) and a phenolic resin matrix. The presence of continuous carbon fibers provides superior stiffness and strength compared to legacy TPS, while the 3D weave pattern provides a great deal of design flexibility for both in-plane and through thickness thermomechanical behavior. However, modeling of 3D woven composites is notoriously complex and numerically intensive. The present investigation utilizes a unique ultra-efficient approach, known as Multiscale Recursive Micromechanics (MsRM), wherein recursive semi-analytical micromechanics methods are employed at various length scales within the composite. The MsRM approach has recently been extended to solve for the effective thermal conductivity as well as the local temperature and thermal flux fields throughout the composite. Presented model results focus on the impact of the microstructural geometry representation at each length scale on the material’s effective thermal conductivity, along with the local thermal flux and temperature fields induced in the microstructures, for a novel 3D woven TPS.

Composite↗