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NASA NTRS2013

Hypersonic Inflatable Aerodynamic Decelerator (HIAD) Technology Development Overview

The successful flight of the Inflatable Reentry Vehicle Experiment (IRVE)-3 has further demonstrated the potential value of Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. This technology development effort is funded by NASA's Space Technology Mission Directorate (STMD) Game Changing Development Program (GCDP). This paper provides an overview of a multi-year HIAD technology development effort, detailing the projects completed to date and the additional testing planned for the future. The effort was divided into three areas: Flexible Systems Development (FSD), Mission Advanced Entry Concepts (AEC), and Flight Validation. FSD consists of a Flexible Thermal Protection Systems (FTPS) element, which is investigating high temperature materials, coatings, and additives for use in the bladder, insulator, and heat shield layers; and an Inflatable Structures (IS) element which includes manufacture and testing (laboratory and wind tunnel) of inflatable structures and their associated structural elements. AEC consists of the Mission Applications element developing concepts (including payload interfaces) for missions at multiple destinations for the purpose of demonstrating the benefits and need for the HIAD technology as well as the Next Generation Subsystems element. Ground test development has been pursued in parallel with the Flight Validation IRVE-3 flight test. A larger scale (6m diameter) HIAD inflatable structure was constructed and aerodynamically tested in the National Full-scale Aerodynamics Complex (NFAC) 40ft by 80ft test section along with a duplicate of the IRVE-3 3m article. Both the 6m and 3m articles were tested with instrumented aerodynamic covers which incorporated an array of pressure taps to capture surface pressure distribution to validate Computational Fluid Dynamics (CFD) model predictions of surface pressure distribution. The 3m article also had a duplicate IRVE-3 Thermal Protection System (TPS) to test in addition to testing with the Aerocover configuration. Both the Aerocovers and the TPS were populated with high contrast targets so that photogrammetric solutions of the loaded surface could be created. These solutions both refined the aerodynamic shape for CFD modeling and provided a deformed shape to validate structural Finite Element Analysis (FEA) models. Extensive aerothermal testing has been performed on the TPS candidates. This testing has been conducted in several facilities across the country. The majority of the testing has been conducted in the Boeing Large Core Arc Tunnel (LCAT). HIAD is continuing to mature testing methodology in this facility and is developing new test sample fixtures and control methodologies to improve understanding and quality of the environments to which the samples are subjected. Additional testing has been and continues to be performed in the NASA LaRC 8ft High Temperature Tunnel, where samples up to 2ft by 2ft are being tested over representative underlying structures incorporating construction features such as sewn seams and through-thickness quilting. With the successful completion to the IRVE-3 flight demonstration, mission planning efforts are ramping up on the development of the HIAD Earth Atmospheric Reenty Test (HEART) which will demonstrate a relevant scale vehicle in relevant environments via a large-scale aeroshell (approximately 8.5m) entering at orbital velocity (approximately 7km/sec) with an entry mass on the order of 4MT. Also, the Build to Print (BTP) hardware built as a risk mitigation for the IRVE-3 project to have a "spare" ready to go in the event of a launch vehicle delivery failure is now available for an additional sub-orbital flight experiment. Mission planning is underway to define a mission that can utilize this existing hardware and help the HIAD project further mature this technology.

Hughes, Stephen J.↗

NASA NTRS2013

Thermal Protection Materials and Systems: Past, Present, and Future

Thermal protection materials and systems (TPS) protect vehicles from the heat generated when entering a planetary atmosphere. NASA has developed many TPS systems over the years for vehicle ranging from planetary probes to crewed vehicles. The goal for all TPS is efficient and reliable performance. Efficient means using the right material for the environment and minimizing the mass of the heat shield without compromising safety. Efficiency is critical if the payload such as science experiments is to be maximized on a particular vehicle. Reliable means that we understand and can predict performance of the material. Although much characterization and testing of materials is performed to qualify and certify them for flight, it is not possible to completely recreate the reentry conditions in test facilities, and flight-testing

Johnson, Sylvia M.↗

NASA NTRS2013

Enabling a Better Aft Heat Shield Solution for Future Mars Science Laboratory Class Vehicles

System studies are described that compare masses and estimated manufacturing costs of options for the as‐flown Mars Science Laboratory (MSL) aft body Thermal Light Weight Ablator (SLA) 561‐V and its thickness was not optimized using the standard TPS Sizer Tool widely used for heat shield design. Use of the TPS sizing tool suggests that optimization of the SLA thickness could reduce the aft heat shield mass by 40 percent. Analysis of the predicted aft‐shell aerothermodynamics suggests that the bulk of MSL class entry vehicle heat shields could incorporate Advanced Flexible Reusable Surface Insulation (AFRSI). AFRSI has a wellestablished record of relatively inexpensive manufacturing and flight certification based on its use on the lee side of the Space Shuttle. Runs with the TPS Sizer show that the AFRSI solution would be 60 percent lighter than the as‐flown SLA. The issue of Reaction Control System (RCS) heating on the aft shell could be addressed by locally impregnating the AFRSI with silicone to enhance its robustness to short bursts ofheating. Stagnation point arcjet testing has shown that silicone impregnated AFRSI performs well at heat rates of 115 W/cm2 and 0.1 atmospheres for a duration of 40 seconds, far beyond conditions that are expected for MSL class vehicles. The paper concludes with a discussion of manufacturing processes for AFRSI, impregnation approaches and relative cost comparisons to the SLA solution.

McGuire, Mary K.↗

NASA NTRS2013

Development of FIAT-Based Parametric Thermal Protection System Mass Estimating Relationships for NASA's Multi-Mission Earth Entry Concept

Part of NASAs In-Space Propulsion Technology (ISPT) program is the development of the tradespace to support the design of a family of multi-mission Earth Entry Vehicles (MMEEV) to meet a wide range of mission requirements. An integrated tool called the Multi Mission System Analysis for Planetary Entry Descent and Landing or M-SAPE tool is being developed as part of Entry Vehicle Technology project under In-Space Technology program. The analysis and design of an Earth Entry Vehicle (EEV) is multidisciplinary in nature, requiring the application many disciplines. Part of M-SAPE's application required the development of parametric mass estimating relationships (MERs) to determine the vehicle's required Thermal Protection System (TPS) for safe Earth entry. For this analysis, the heat shield was assumed to be made of a constant thickness TPS. This resulting MERs will then e used to determine the pre-flight mass of the TPS. Two Mers have been developed for the vehicle forebaody. One MER was developed for PICA and the other consisting of Carbon Phenolic atop an Advanced Carbon-Carbon composition. For the the backshell, MERs have been developed for SIRCA, Acusil II, and LI-900. How these MERs were developed, the resulting equations, model limitations, and model accuracy are discussed in this poster.

Sepka, Steven A.↗

NASA NTRS2013

Mechanical Testing of Carbon Based Woven Thermal Protection Materials

Three Dimensional Woven thermal protection system (TPS) materials are one of the enabling technologies for mechanically deployable hypersonic decelerator systems. These materials have been shown capable of serving a dual purpose as TPS and as structural load bearing members during entry and descent operations. In order to ensure successful structural performance, it is important to characterize the mechanical properties of these materials prior to and post exposure to entry-like heating conditions. This research focuses on the changes in load bearing capacity of woven TPS materials after being subjected to arcjet simulations of entry heating. Preliminary testing of arcjet tested materials [1] has shown a mechanical degradation. However, their residual strength is significantly more than the requirements for a mission to Venus [2]. A systematic investigation at the macro and microstructural scales is reported here to explore the potential causes of this degradation. The effects of heating on the sizing (an epoxy resin coating used to reduce friction and wear during fiber handling) are discussed as one of the possible causes for the decrease in mechanical properties. This investigation also provides valuable guidelines for margin policies for future mechanically deployable entry systems.

Pham, John↗

NASA NTRS2014

Extending Our Understanding of Compliant Thermal Barrier Performance

Thermal barriers and seals are integral components in the thermal protection systems (TPS) of nearly all aerospace vehicles. They are used to minimize the flow of hot gases through interfaces and protect underlying temperature-sensitive components and systems. Although thermal barriers have been used extensively on many aerospace vehicles, the factors affecting their thermal and mechanical performance are not well-understood. Because of this, vehicle TPS designers are often left with little guidance on how to properly design and optimize these barriers. An ongoing effort to better understand thermal barrier performance and develop models and design tools is in progress at the NASA Glenn Research Center. Testing has been conducted to understand the degree to which insulation density influences structural performance and permeability. In addition, the development of both thermal and mechanical models is ongoing with the goal of providing an improved ability to design and implement these critical TPS components.

high temperature↗

NASA NTRS2015

Smart Book Charts

Smart book charts for TPSM: Heatshield for Extreme Entry Environment Technology (HEEET), Conformal Ablative TPS (CA-TPS), 3D Woven Multifunctional Ablative TPS (3D MAT), and Adaptable, Deployable, Entry and Placement Technology (ADEPT).

Conformal Ablative↗

NASA NTRS2015

Determination of Acreage Thermal Protection Foam Loss From Ice and Foam Impacts

A parametric study was conducted to establish Thermal Protection System (TPS) loss from foam and ice impact conditions similar to what might occur on the Space Launch System. This study was based upon the large amount of testing and analysis that was conducted with both ice and foam debris impacts on TPS acreage foam for the Space Shuttle Project External Tank. Test verified material models and modeling techniques that resulted from Space Shuttle related testing were utilized for this parametric study. Parameters varied include projectile mass, impact velocity and impact angle (5 degree and 10 degree impacts). The amount of TPS acreage foam loss as a result of the various impact conditions is presented.

Thermal Protection System↗

NASA NTRS2016

After Math - Foamology and Flight Rationale

The Space Shuttle was developed by NASA to be a largely reusable launch system which could provide frequent access to low earth orbit. Like all previous launch systems, safe reentry for the crew and payload required the use of a thermal protection system (TPS). Unlike previous spacecraft though, the Shuttle's TPS was exposed from launch, making it sensitive to debris which could be generated by the vehicle on ascent. The most likely and potentially destructive source of debris was considered to be ice, which could build-up anywhere on the External Tank (ET) where there was exposed metal. Ice could form during ground operations after the cryogenic propellants had been loaded and then be knocked loose on ascent. In order to prevent both ice build-up and boil-off of the propellants, the entire ET and all protuberances (orbiter attach points, pressurization lines, propellant feed lines, etc.) were covered with a spray on foam insulation (SOFI) type TPS. Unfortunately the foam was also susceptible to liberation during ascent, and posed a debris risk of its own. During the early years of the Shuttle Program engineers spent a good deal of effort characterizing the amount of foam that was shed.

Steva, Thomas↗

NASA NTRS2014

An Update to a Conformal Ablative Thermal Protection System for Planetary and Human Exploration Missions

As described at IPPW-10, in FY12, the CA-TPS element focused on establishing materials requirements based on MSL-type and COTS Low Earth orbit (LEO) conditions (q 250 Wcm2) to develop and deliver a conformal ablative TPS. This involved down selecting, manufacturing and testing two of the best candidate materials, demonstrating uniform infiltration of resins into baseline 2-cm thick carbon felt, selecting a primary conformal material formulation based on novel arc jet and basic material properties testing, developing and demonstrating instrumentation for felt-based materials and, based on the data, developing a low fidelity material response model so that the conformal ablator TPS thickness for missions could be established. In addition, the project began to develop Industry Partnerships. Since the nominal thickness of baseline carbon felts was only 2-cm, a partnership with a rayon felt developer was made in order to upgrade equipment, establish the processes required and attempt to manufacture 10-cm thick white goods. A partnership with a processing house was made to develop the methodology to carbonize large pieces of the white goods into 7.5-cm thick carbon felt. In FY13, more advanced testing and modeling of the down selected conformal material was performed. Material thermal properties tests and structural properties tests were performed. The first 3 and 4-point bend tests were performed on the conformal ablator as well as PICA for comparison and the conformal ablator had outstanding behavior compared to PICA. Arc jet testing was performed with instrumented samples of both the conformal ablator and standard PICA at heating rates ranging from 40 to 400 Wcm2 and shear as high as 600 Pa. The results from these tests showed a remarkable improvement in the thermal penetration through the conformal ablator when compared to PICAs response. The data from these tests were used to develop a mid-fidelity thermal response model. Additional arc jet testing in the same conditions on various seam designs were very successful in showing that the material could be joined with a minimum of adhesive and required no complicated gap and gap filler design for installation. In addition, the partnership with industry to manufacture thicker rayon felt was very successful. The vendor made a 2-m wide by 30-m long sample of 10-cm thick rayon felt. When carbonized, the resulting thickness was over 7.5-cm thick, nearly 4 times the thickest off-the-shelf carbon felt. In FY14, the project has initiated a partnership with another vendor to begin the scale-up manufacturing effort. This year, the vendor will duplicate the process and manufacture at the current scale for comparison with NASA-processed materials. Properties testing and arc jet testing will be performed on the vendor-processed materials. Planning for manufacturing large, 1-m x 1-m, panels will begin as well. In FY15, the vendor will then manufacture large panels and the project will build a 2-m x 2-m Manufacturing Demonstration Unit (MDU).

Ablative materials↗

NASA NTRS2016

Optimization of a Hot Structure Aeroshell and Nose Cap for Mars Atmospheric Entry

The National Aeronautics and Space Administration (NASA) is preparing to send humans beyond Low Earth Orbit and eventually to the surface of Mars. As part of the Evolvable Mars Campaign, different vehicle configurations are being designed and considered for delivering large payloads to the surface of Mars. Weight and packing volume are driving factors in the vehicle design, and the thermal protection system (TPS) for planetary entry is a technology area which can offer potential weight and volume savings. The feasibility and potential benefits of a ceramic matrix composite hot structure concept for different vehicle configurations are explored in this paper, including the nose cap for a Hypersonic Inflatable Aerodynamic Decelerator (HIAD) and an aeroshell for a mid lift-to-drag (Mid L/D) concept. The TPS of a planetary entry vehicle is a critical component required to survive the severe aerodynamic heating environment during atmospheric en- try. The current state-of-the-art is an ablative material to protect the vehicle from the heat load. The ablator is bonded to an underlying structure, which carries the mechanical loads associated with entry. The alternative hot structure design utilizes an advanced carbon-carbon material system on the outer surface of the vehicle, which is exposed to the severe heating and acts as a load carrying structure. The preliminary design using the hot structure concept and the ablative concept is determined for the spherical nose cap of the HIAD entry vehicle and the aeroshell of the Mid L/D entry vehicle. The results of the study indicate that the use of hot structures for both vehicle concepts leads to a feasible design with potential weight and volume savings benefits over current state-of-the-art TPS technology that could enable future missions.

Langston, Sarah L.↗

NASA NTRS2017

Progress Report on PICA Activities in Support of New Frontiers Missions

Phenolic Impregnated Carbon Ablator (PICA) is a TPS material that has been used in a number of previous flight missions (Stardust, MSL) and is planned for a number of future missions (OSIRIS-Rex and Mars 2020) so it has substantial flight heritage, is applicable to a wide range of missions, and is often baselined as the TPS in future NASA proposal activities. As is common with a number of TPS materials, PICA faces a supply chain issue with the rayon precursor from which the carbon fibers used in the PICA preform are derived. PICA uses a non-woven form of the rayon, which once carbonized, is used in the low-density carbon FiberForm (carbon tile) preform utilized in PICA. Current PICA uses a NASA-qualified non-domestic rayon supplier (Sniace), however the qualified supplier is no longer manufacturing the rayon materials. This activity will address PICA sustainability, by initially carbonizing the remaining stockpile of Sniace rayon precursor. A additional FiberForm manufacturing task from alternate rayon sources is also in progress.

thermal protection↗

NASA NTRS2016

Kepler Data Validation Time Series File: Description of File Format and Content

The Kepler space mission searches its time series data for periodic, transit-like signatures. The ephemerides of these events, called Threshold Crossing Events (TCEs), are reported in the TCE tables at the NASA Exoplanet Archive (NExScI). Those TCEs are then further evaluated to create planet candidates and populate the Kepler Objects of Interest (KOI) table, also hosted at the Exoplanet Archive. The search, evaluation and export of TCEs is performed by two pipeline modules, TPS (Transit Planet Search) and DV (Data Validation). TPS searches for the strongest, believable signal and then sends that information to DV to fit a transit model, compute various statistics, and remove the transit events so that the light curve can be searched for other TCEs. More on how this search is done and on the creation of the TCE table can be found in Tenenbaum et al. (2012), Seader et al. (2015), Jenkins (2002). For each star with at least one TCE, the pipeline exports a file that contains the light curves used by TPS and DV to find and evaluate the TCE(s). This document describes the content of these DV time series files, and this introduction provides a bit of context for how the data in these files are used by the pipeline.

DV Time Series↗

NASA NTRS2017

Mars 2020 Entry, Descent, and Landing Instrumentation 2 (MEDLI2) Sensor Suite

The Mars 2020 Entry, Descent, and Landing Instrumentation 2 (MEDLI2) sensor suite seeks to address the aerodynamic, aerothermodynamic, and thermal protection system (TPS) performance issues during atmospheric entry, descent, and landing of the Mars 2020 mission. Based on the highly successful instrumentation suite that flew on Mars Science Laboratory (MEDLI), the new sensor suite expands on the types of measurements and also seeks to answer questions not fully addressed by the previous mission. Sensor Package: MEDLI2 consists of 7 pressure transducers, 17 thermal plugs, 2 heat flux sensors, and one radiometer. The sensors are distributed across both the heatshield and backshell, unlike MEDLI (the first sensor suite), which was located solely on the heat-shield. The sensors will measure supersonic pressure on the forebody, a pressure measurement on the aftbody, near-surface and in-depth temperatures in the heatshield and backshell TPS materials, direct total heat flux on the aftbody, and direct radiative heating on the aftbody. Instrument Development: The supersonic pressure transducers, the direct heat flux sensors, and the radiometer all were tested during the development phase. The status of these sensors, including the piezo-resistive pressure sensors, will be presented. The current plans for qualification and calibration for all of the sensors will also be discussed. Post-Flight Data Analysis: Similar to MEDLI, the estimated flight trajectory will be reconstructed from the data. The aerodynamic parameters that will be reconstructed will be the axial force coefficient, freestream Mach number, base pressure, atmospheric density, and winds. The aerothermal quantities that will be determined are the heatshield and backshell aero-heating, turbulence transition across the heatshield, and TPS in-depth performance of PICA. By directly measuring the radiative and total heat fluxes on the back-shell, the convective portion of the heat flux will be estimated. The status of the current tools to perform the post-flight data analysis will be presented, along with plans for model improvements.

Hwang, Helen H.↗

NASA NTRS2017

Mars 2020 Entry, Descent, and Landing Instrumentation 2 (MEDLI2) Sensor Suite

Hwang, Helen↗

NASA NTRS2017

Kepler Planet Detection Metrics: Window and One-Sigma Depth Functions for Data Release 25

This document describes the window and one-sigma depth functions relevant to the Transiting Planet Search (TPS) algorithm in the Kepler pipeline (Jenkins 2002; Jenkins et al. 2017). The window function specifies the fraction of unique orbital ephemeris epochs over which three transits are observable as a function of orbital period. In this context, the epoch and orbital period, together, comprise the ephemeris of an orbiting companion, and ephemerides with the same period are considered equivalent if their epochs differ by an integer multiple of the period. The one-sigma depth function specifies the depth of a signal (in ppm) for a given light curve that results in a one-sigma detection of a transit signature as a function of orbital period when averaged over all unique orbital ephemerides. These planet detection metrics quantify the ability of TPS to detect a transiting planet signature on a star-by-star basis. They are uniquely applicable to a specific Kepler data release, since they are dependent on the details of the light curves searched and the functionality of the TPS algorithm used to perform the search. This document describes the window and one-sigma depth functions relevant to Kepler Data Release 25 (DR25), where the data were processed (Thompson et al. 2016) and searched (Twicken et al. 2016) with the SOC 9.3 pipeline. In Section 4, we describe significant differences from those reported in Kepler Data Release 24 (Burke Seader 2016) and document our verification method.

Planet Detection Metrics↗

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 NTRS2018

Mars Sample Return: Grand Challenge for EDL

A year ago, I gave a talk in anticipation of a Mars Sample Return effort at the 9th Ablation Workshop. Since then a lot has happened. "April of this year, after a year of study phase, NASA and ESA (European Space Agency) signed a Statement of Intent (SOI) to jointly develop a Mars Sample Return plan to be submitted to their respective authorities by the end of 2019. This signing is historic, as it signals the desire, the readiness, and the willingness to work together to execute this inspiring mission, we all have the opportunity to tackle this grand challenge. We have the scientific and engineering maturity to identify the critical technologies ready to be applied, and with discipline this campaign can be executed affordably," Jim Watzin, Mars Program Executive, NASA. NASA Centers with JPL (Jet Propulsion Laboratory) leading the charge is in the midst of a pre-formulation phase for executing a Mars Sample Return before the end of next decade. The proposed talk builds on the previous year talk. In light of the agreement between NASA and ESA, NASA has assumed the responsibilities for developing the earth entry vehicle (EEV) that will fly along with a European Spacecraft and return with the sample from Mars. EEV will be deployed for entry into earth. The EEV design, development, testing and certification have to result in a highly reliable sample return system. The entire architecture has to be demonstrated to meet the planetary protection requirement. NASA is considering two distinctly different earth entry vehicle architectures and with each choice, many different ablative TPS (Thermal Protective Shield) candidates. As a result of the NASA-ESA ongoing studies, some of the key entry conditions and design requirements are better understood today and more are being scoped out. The heat-shield ablative TPS choice need to be done with a good understanding as it plays a very significant role in determining the robustness of the EEV. Knowledge about how materials and system perform, and how the features could become flaws and how flaws lead to failure, etc. need to be clearly understood and the knowledge then need to be used to down select the TPS. This proposed talk will provide greater insight into the progress being made and the challenges that need to be tackled.

Mars Sample Return: Grand Challenge for EDL↗