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Structural analyses for the modification and verification of the Viking aeroshell

The Viking aeroshell is an extremely lightweight flexible shell structure that has undergone thorough buckling analyses in the course of its development. The analytical tools and modeling technique required to reveal the structural behavior are presented. Significant results are given which illustrate the complex failure modes not usually observed in simple models and analyses. Both shell-of-revolution analysis for the pressure loads and thermal loads during entry and a general shell analysis for concentrated tank loads during launch were used. In many cases fixes or alterations to the structure were required, and the role of the analytical results in determining these modifications is indicated.

Stephens, W. B.

Thermal stress response of General Purpose Heat Source (GPHS) aeroshell material

A thermal stress test was conducted to determine the ability of the GPHS aeroshell 3 D FWPF material to maintain physical integrity when exposed to a severe heat flux such as would occur from prompt reentry of GPHS modules. The test was performed in the Giant Planetary Facility at NASA's Ames Research Center. Good agreement was obtained between the theoretical and experimental results for both temperature and strain time histories. No physical damage was observed in the test specimen. These results provide initial corroboration both of the analysis techniques and that the GPHS reentry member will survive the reentry thermal stress levels expected.

Grinberg, I. M.

Inviscid Flow Computations of Several Aeroshell Configurations for a '07 Mars Lander

This report documents the results of an inviscid computational study conducted on several candidate aeroshell configurations for a proposed '07 Mars lander. Eleven different configurations were considered, and the aerodynamic characteristics of each of these were computed for a Mach number of 23.7 at 10, 15, and 20 degree angles of attack. The unstructured grid software FELISA with the equilibrium Mars gas option was used for these computations. The pitching moment characteristics and the lift-to-drag ratios at trim angle of attack of each of these configurations were examined to make a selection. The criterion for selection was that the configuration should be longitudinally stable, and should trim at an angle of attack where the L/D is -0.25. Based on the present study, two configurations were selected for further study

Prabhu, Ramadas K.

Superalloy Foams for Aeroshell Applications

Current thermal protection systems for reentry from space, such as that employed on the space shuttle, rely on ceramic tiles with ultra-low conductivity. These materials provide excellent thermal protection but are extremely fragile, easily degraded by environmental attack, and carry no structural loads. Future thermal protection systems being proposed in NASAs MITAS Program will attempt to combine thermal protection with improved durability and structural capability without significant increases in vehicle weight. This may be accomplished by combining several materials in a layered structure to obtain the desired function for aeroshell applications. One class of materials being considered for inclusion in this concept are high temperature metal foam. The objective of this paper was to fabricate low density, superalloy foams and conduct limited testing to evaluate their thermal and structural capabilities. Superalloys were chosen for evaluation as they possesses good strength and excellent environmental endurance over a wide range of temperatures. Utilizing superalloys as low density foams, with porosity contents greater than 90%, minimizes weight and thermal conductivity.

Gayda, John

An Inviscid Computational Study of Three '07 Mars Lander Aeroshell Configurations Over a Mach Number Range of 2.3 to 4.5

This report documents the results of a study conducted to compute the inviscid longitudinal aerodynamic characteristics of three aeroshell configurations of the proposed '07 Mars lander. This was done in support of the activity to design a smart lander for the proposed '07 Mars mission. In addition to the three configurations with tabs designated as the shelf, the canted, and the Ames, the baseline configuration (without tab) was also studied. The unstructured grid inviscid CFD software FELISA was used, and the longitudinal aerodynamic characteristics of the four configurations were computed for Mach number of 2.3, 2.7, 3.5, and 4.5, and for an angle of attack range of -4 to 20 degrees. Wind tunnel tests had been conducted on scale models of these four configurations in the Unitary Plan Wind Tunnel, NASA Langley Research Center. Present computational results are compared with the data from these tests. Some differences are noticed between the two results, particularly at the lower Mach numbers. These differences are attributed to the pressures acting on the aft body. Most of the present computations were done on the forebody only. Additional computations were done on the full body (forebody and afterbody) for the baseline and the Shelf configurations. Results of some computations done (to simulate flight conditions) with the Mars gas option and with an effective gamma are also included.

Prabhu, Ramadas K.

Heat Shield Cavity Parametric Experimental Aeroheating for a Proposed Mars Smart Lander Aeroshell

The proposed Mars Smart Lander is to be attached through its aeroshell to the main spacecraft bus, thereby producing cavities in the heat shield. To study the effects these cavities will have on the heating levels experienced by the heat shield, an experimental aeroheating investigation was performed at the NASA Langley Research Center in the 20-Inch Mach 6 Air Tunnel. The effects of Reynolds number, angle-of-attack, and cavity size and location on aero-heating levels and distributions were determined and are presented. To aid the discussion on the effects of the cavities, laminar, thin-layer Navier-Stokes flow field solutions were post-processed to calculate relevant boundary layer properties such as boundary layer height and momentum thickness, edge Mach number, and streamwise pressure gradient. It was found that the effect of the cavities varies with angle-of-attack, freestream Reynolds number, and cavity size and location. The presence of a cavity raised the downstream heating rates by as much as 325% as a result of boundary layer transition.

Liechty, Derek S.

Managing Uncertainty in Preliminary Aeroshell Design Analysis

An analysis tool to aid in preliminary design of re-entry aeroshells for interplanetary exploration is presented. The computational tool addresses a common feature of design analysis, the need to make use of results from several analysis regimes and from several sources.

Design Methods and Models Design Representations C

Thermal Engineering of Mars Entry Carbon/Carbon Non-Ablative Aeroshell - Part 2

Candidate Aeroshell Test models composed of a quasi-isotropic Carbon/Carbon (C/C) front face sheet (F/S), eggcrate core, C/C back F/S, Carbon Aerogel insulation, C/C radiation shield and the C/C close-out were constructed based on the analytical temperature predictions presented in Part One of this work.

Mars entry vehicle

Fully Automated Single-Zone Elliptic Grid Generation for Mars Science Laboratory (MSL) Aeroshell and Canopy Geometries

A procedure for generating smooth uniformly clustered single-zone grids using enhanced elliptic grid generation has been demonstrated here for the Mars Science Laboratory (MSL) geometries such as aeroshell and canopy. The procedure obviates the need for generating multizone grids for such geometries, as reported in the literature. This has been possible because the enhanced elliptic grid generator automatically generates clustered grids without manual prescription of decay parameters needed with the conventional approach. In fact, these decay parameters are calculated as decay functions as part of the solution, and they are not constant over a given boundary. Since these decay functions vary over a given boundary, orthogonal grids near any arbitrary boundary can be clustered automatically without having to break up the boundaries and the corresponding interior domains into various zones for grid generation.

kaul, Upender K.

Atmospheric Entry Studies for Venus Missions: 45 Sphere-Cone Rigid Aeroshells and Ballistic Entries

The present study considers direct ballistic entries into the atmosphere of Venus using a 45deg sphere-cone rigid aeroshell, a legacy shape that has been used successfully in the past in the Pioneer Venus Multiprobe Mission. For a number of entry mass and heatshield diameter combinations (i.e., various ballistic coefficients) and entry velocities, the trajectory space in terms of entry flight path angles between skip out and -30deg is explored with a 3DoF trajectory code, TRAJ. From these trajectories, the viable entry flight path angle space is determined through the use of mechanical and thermal performance limits on the thermal protection material and science payload; the thermal protection material of choice is entry-grade carbon phenolic, for which a material thermal response model is available. For mechanical performance, a 200 g limit is placed on the peak deceleration load experienced by the science instruments, and 10 bar is assumed as the pressure limit for entry-grade carbon-phenolic material. For thermal performance, inflection points in the total heat load distribution are used as cut off criteria. Analysis of the results shows the existence of a range of critical ballistic coefficients beyond which the steepest possible entries are determined by the pressure limit of the material rather than the deceleration load limit.

Prabhu, Dinesh K.

Finite Element Modeling and Analysis of Mars Entry Aeroshell Baseline Concept

The structure that is developed and analyzed in this project must be able to survive all the various load conditions that it will encounter along its course to Mars with the minimal amount of weight and material. At this stage, the goal is to study the capability of the structure using a finite element model (FEM). This FEM is created using a python script, and is numerically solved in Nastran. The purpose of the model is to achieve an optimization of mass given specific constraints on launch and entry. The generation and analysis of the baseline Rigid Mid-Range Lift to Drag Ratio Aeroshell model is a continuation and an improvement on previous work done for the FEM. The model is generated using Python programming with the axisymmetric placement of nodes for beam and shell elements. The shells are assigned a honeycomb sandwich material with an aluminum honeycomb core and composite face sheets, and the beams are assigned the same material as the shell face sheets. There are two load cases assigned to the model: Earth launch and Mars entry. The Earth launch case consists of pressure, gravity, and vibration loads, and the Mars entry case consists of just pressure and gravity loads. The Earth launch case was determined to be the driving case, though the analyses are performed for both cases to ensure the constraints are satisfied. The types of analysis performed with the model are design optimization, statics, buckling, normal modes, and frequency response, the last of which is only for the Earth launch load case. The final results indicated that all of the requirements are satisfied except the thermal limits, which could not yet be tested, and the normal modes for the Mars entry. However, the frequency limits during Mars entry are expected to be much higher than the lower frequency limits set for the analysis. In addition, there are still improvements that can be made in order to reduce the weight while still meeting all requirements.

Ahmed, Samee W.

Optimization of a Multifunctional Hot Structure Aeroshell for Mars Entry

Vehicle size and weight are driving cost factors in sending vehicles into space because the cost of launch is directly related to the payload mass being delivered. Vehicle size and weight have a larger impact on deep- space missions compared to sending a payload to low Earth orbit due to the extra fuel and supplies required to complete the longer duration mission. One area of study for possible vehicle volume or weight reduction is the thermal protection system (TPS) of a vehicle. Hot structures have been proposed as a TPS concept which can carry both primary structural loads and thermal loads. The use of hot structures on a Mars entry vehicle may be feasible and have potential volume and weight savings over the current state of the art ablative TPS technology. A preliminary trade study was performed on a mid lift-to-drag aeroshell Mars entry concept vehicle; comparing the weight and skin thickness of a vehicle using ablative TPS with a vehicle using hot structures. Independent thermal and structural analyses were performed to determine the minimum mass designs. The goal of this study was to determine if the use of hot structures was feasible and had potential for significant vehicle volume and weight savings over the current state of the art. This trade study found that use of a hot structures leads to a feasible alternative to ablative TPS technology, with potential 53% weight and 22% thickness (volume) saving benefits that could enable future missions.

Langston, Sarah L.

Venus Cloud Layer Investigation: Aeroshells for Entry, Descent and Deployment

Entry, Descent and Deployment (EDD) of aerial platforms at Venus follows similar operational approach as landers. •Limited only by the availability of mass efficient and robust aeroshell (heatshield/TPS) technology. •Heatshield for Extreme Entry Environment Technology (HEEET) at TRL 6 is an enabler of Venus in-situ missions.Lower ballistic coefficient, deployable concept, ADEPT, offers additional options•Low deceleration entry profile•Release of one or more payloads (balloons) from open back of the entry vehicle2

Venus

Simulations of Coupled Shoulder Ablation of A Conceptual Aeroshell

The current study explores coupled numerical simulations of flow dynamics and material response affect ablation of the shoulder region of an entry capsule used in space missions like the Mars Sample Return (MSR) project. A new computational tool named Ares, developed at NASA Ames Research Center, is applied to carry out the coupled simulations by interconnecting well-established US3D (flow solver) and Icarus (material response solver), and the material considered is three-dimensional mid-density carbon phenolic (3MDCP). Particularly, this work extends the uncoupled analysis of Shrestha et al. 2022 by incorporating the coupling mechanism across the ablating surface between fluid and the capsule geometry. For simplicity, an axisymmetric geometry of the entry system is considered. A few mission-relevant parametric studies such as angles of orientation of the material layers with respect to the streamwise direction, backshell boundary conditions, and alternation of convective heat-transfer coefficients are investigated to essentially explore Ares capability with the primary focus on shoulder location.

Coupled Ablation Modeling