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NASA NTRS2015

Orion Launch Abort System Performance on Exploration Flight Test 1

This paper will present an overview of the flight test objectives and performance of the Orion Launch Abort System during Exploration Flight Test-1. Exploration Flight Test-1, the first flight test of the Orion spacecraft, was managed and led by the Orion prime contractor, Lockheed Martin, and launched atop a United Launch Alliance Delta IV Heavy rocket. This flight test was a two-orbit, high-apogee, high-energy entry, low-inclination test mission used to validate and test systems critical to crew safety. This test included the first flight test of the Launch Abort System preforming Orion nominal flight mission critical objectives. NASA is currently designing and testing the Orion Multi-Purpose Crew Vehicle (MPCV). Orion will serve as NASA's new exploration vehicle to carry astronauts to deep space destinations and safely return them to earth. The Orion spacecraft is composed of four main elements: the Launch Abort System, the Crew Module, the Service Module, and the Spacecraft Adapter (Fig. 1). The Launch Abort System (LAS) provides two functions; during nominal launches, the LAS provides protection for the Crew Module from atmospheric loads and heating during first stage flight and during emergencies provides a reliable abort capability for aborts that occur within the atmosphere. The Orion Launch Abort System (LAS) consists of an Abort Motor to provide the abort separation from the Launch Vehicle, an Attitude Control Motor to provide attitude and rate control, and a Jettison Motor for crew module to LAS separation (Fig. 2). The jettison motor is used during a nominal launch to separate the LAS from the Launch Vehicle (LV) early in the flight of the second stage when it is no longer needed for aborts and at the end of an LAS abort sequence to enable deployment of the crew module's Landing Recovery System. The LAS also provides a Boost Protective Cover fairing that shields the crew module from debris and the aero-thermal environment during ascent. Although the Orion Program has tested a number of the critical systems of the Orion spacecraft on the ground, the launch environment cannot be replicated completely on Earth. A number of flight tests have been conducted and are planned to demonstrate the performance and enable certification of the Orion Spacecraft. Exploration Flight Test 1, the first flight test of the Orion spacecraft, was successfully flown on December 5, 2014 from Cape Canaveral Air Force Station's Space Launch Complex 37. Orion's first flight was a two-orbit, high-apogee, high-energy entry, low-inclination test mission used to validate and test systems critical to crew safety, such as heat shield performance, separation events, avionics and software performance, attitude control and guidance, parachute deployment and recovery operations. One of the key separation events tested during this flight was the nominal jettison of the LAS. Data from this flight will be used to verify the function of the jettison motor to separate the Launch Abort System from the crew module so it can continue on with the mission. The LAS nominal jettison event on Exploration Flight Test 1 occurred at six minutes and twenty seconds after liftoff (See Fig. 3). The abort motor and attitude control motors were inert for Exploration Flight Test 1, since the mission did not require abort capabilities. A suite of developmental flight instrumentation was included on the flight test to provide data on spacecraft subsystems and separation events. This paper will focus on the flight test objectives and performance of the LAS during ascent and nominal jettison. Selected LAS subsystem flight test data will be presented and discussed in the paper. Exploration Flight Test -1 will provide critical data that will enable engineering to improve Orion's design and reduce risk for the astronauts it will protect as NASA continues to move forward on its human journey to Mars. The lessons learned from Exploration Flight Test 1 and the other Flight Test Vehicles will certainly contribute to the vehicle architecture of a human-rated space launch vehicle.

McCauley, R.↗

NASA NTRS2015

Additive Manufacturing of SiC Based Ceramics and Ceramic Matrix Composites

Silicon carbide (SiC) ceramics and SiC fiber reinforcedSiC ceramic matrix composites (SiCSiC CMCs) offer high payoff as replacements for metals in turbine engine applications due to their lighter weight, higher temperature capability, and lower cooling requirements. Additive manufacturing approaches can offer game changing technologies for the quick and low cost fabrication of parts with much greater design freedom and geometric complexity. Four approaches for developing these materials are presented. The first two utilize low cost 3D printers. The first uses pre-ceramic pastes developed as feed materials which are converted to SiC after firing. The second uses wood containing filament to print a carbonaceous preform which is infiltrated with a pre-ceramic polymer and converted to SiC. The other two approaches pursue the AM of CMCs. The first is binder jet SiC powder processing in collaboration with rp+m (Rapid Prototyping+Manufacturing). Processing optimization was pursued through SiC powder blending, infiltration with and without SiC nano powder loading, and integration of nanofibers into the powder bed. The second approach was laminated object manufacturing (LOM) in which fiber prepregs and laminates are cut to shape by a laser and stacked to form the desired part. Scanning electron microscopy was conducted on materials from all approaches with select approaches also characterized with XRD, TGA, and bend testing.

3-D printing↗

NASA NTRS2015

Ultra High Temperature (UHT) SiC Fiber (Phase 2)

Silicon-carbide fiber-reinforced silicon-carbide ceramic matrix composites (SiCSiC CMC) are emerginglightweight re-usable structural materials not only for hot section components in gas turbine engines, but also for controlsurfaces and leading edges of reusable hypersonic vehicles as well as for nuclear propulsion and reactor components. Ithas been shown that when these CMC are employed in engine hot-section components, the higher the upper usetemperature (UUT) of the SiC fiber, the more performance benefits are accrued, such as higher operating temperatures,reduced component cooling air, reduced fuel consumption, and reduced emissions. The first generation of SiCSiC CMC with a temperature capability of 2200-2400F are on the verge of being introduced into the hot-section components ofcommercial and military gas turbine engines.Today the SiC fiber type currently recognized as the worlds best in terms ofthermo-mechanical performance is the Sylramic-iBN fiber. This fiber was previously developed by the PI at NASA GRC using patented processes to improve the high-cost commercial Sylramic fiber, which in turn was derived from anotherlow-cost low-performance commercial fiber. Although the Sylramic-iBN fiber shows state-of-the art creep and rupture resistance for use temperatures above 2550oF, NASA has shown by fundamental creep studies and model developmentthat its microstructure and creep resistance could theoretically be significantly improved to produce an Ultra HighTemperature (UHT) SiC fiber.This Phase II Seedling Fund effort has been focused on the key objective of effectively repeating the similar processes used for producing the Sylramic-iBN fiber using a design of experiments approach to first understand the cause of the less than optimum Sylramic-iBN microstructure and then attempting to develop processconditions that eliminate or minimize these key microstructural issues. In so doing, it is predicted that that theseadvanced process could result in an UHT SiC fiber with 20 times more creep resistance than the Sylramic-iBN fiber,which in turn would allow SiCSiC CMC to operate up to 2700oF and above, thereby further enhancing the performancebenefits of SiCSiC components in aero-propulsion engines. It was also envisioned that the fiber processes developedduring Phase II efforts would not only reduce production costs for the UHT fiber by using low-cost precursor fibers andcombined processes, but also allow the UHT fibers to be directly produced in preforms of the precursor fibers, possibly atthe facilities of the CMC fabricator.

SiC Ceramic Fiber↗

NASA NTRS2015

Validation of Rain Rate Retrievals for the Airborne Hurricane Imaging Radiometer (HIRAD)

The NASA Hurricane and Severe Storm Sentinel (HS3) mission is an aircraft field measurements program using NASA's unmanned Global Hawk aircraft system for remote sensing and in situ observations of Atlantic and Caribbean Sea hurricanes. One of the principal microwave instruments is the Hurricane Imaging Radiometer (HIRAD), which measures surface wind speeds and rain rates. For validation of the HIRAD wind speed measurement in hurricanes, there exists a comprehensive set of comparisons with the Stepped Frequency Microwave Radiometer (SFMR) with in situ GPS dropwindsondes [1]. However, for rain rate measurements, there are only indirect correlations with rain imagery from other HS3 remote sensors (e.g., the dual-frequency Ka- & Ku-band doppler radar, HIWRAP), which is only qualitative in nature. However, this paper presents results from an unplanned rain rate measurement validation opportunity that occurred in 2013, when HIRAD flew over an intense tropical squall line that was simultaneously observed by the Tampa NEXRAD meteorological radar (Fig. 1). During this experiment, Global Hawk flying at an altitude of 18 km made 3 passes over the rapidly propagating thunderstorm, while the TAMPA NEXRAD perform volume scans on a 5-minute interval. Using the well-documented NEXRAD Z-R relationship, 2D images of rain rate (mm/hr) were obtained at two altitudes (3 km & 6 km), which serve as surface truth for the HIRAD rain rate retrievals. A preliminary comparison of HIRAD rain rate retrievals (image) for the first pass and the corresponding closest NEXRAD rain image is presented in Fig. 2 & 3. This paper describes the HIRAD instrument, which 1D synthetic-aperture thinned array radiometer (STAR) developed by NASA Marshall Space Flight Center [2]. The rain rate retrieval algorithm, developed by Amarin et al. [3], is based on the maximum likelihood estimation (MLE) technique, which compares the observed Tb's at the HIRAD operating frequencies of 4, 5, 6 and 6.6 GHz with corresponding theoretical Tb values from a forward radiative transfer model (RTM). The optimum solution is the integrated rain rate that minimizes the difference between RTM and observed values. Because the excess Tb from rain comes from the direct upwelling and the indirect reflected downwelling paths through the atmosphere, there are several assumptions made for the 2D rain distribution in the antenna incident plane (crosstrack to flight direction). The opportunity to knowing 2D rain surface truth from NEXRAD at two different altitudes will enable a comprehensive evaluation to be preformed and reported in this paper.

hurricane↗

NASA NTRS2016

Modeling and Simulation of Radiative Compressible Flows in Aerodynamic Heating Arc-Jet Facility

Numerical simulations of an arc heated flow inside NASA's 20 [MW] Aerodynamics heating facility (AHF) are performed in order to investigate the three-dimensional swirling flow and the current distribution inside the wind tunnel. The plasma is considered in Local Thermodynamics Equilibrium(LTE) and is composed of Air-Argon gas mixture. The governing equations are the Navier-Stokes equations that include source terms corresponding to Joule heating and radiative cooling. The former is obtained by solving an electric potential equation, while the latter is calculated using an innovative massively parallel ray-tracing algorithm. The fully coupled system is closed by the thermodynamics relations and transport properties which are obtained from Chapman-Enskog method. A novel strategy was developed in order to enable the flow solver and the radiation calculation to be preformed independently and simultaneously using a different number of processors. Drastic reduction in the computational cost was achieved using this strategy. Details on the numerical methods used for space discretization, time integration and ray-tracing algorithm will be presented. The effect of the radiative cooling on the dynamics of the flow will be investigated. The complete set of equations were implemented within the COOLFluiD Framework. Fig. 1 shows the geometry of the Anode and part of the constrictor of the Aerodynamics heating facility (AHF). Fig. 2 shows the velocity field distribution along (x-y) plane and the streamline in (z-y) plane.

Pasma flows↗

NASA NTRS2015

No-Oven, No-Autoclave Composite Processing

Very large composite structures, such as those used in NASA's Space Launch System, push the boundaries imposed by current autoclaves. New technology is needed to maintain composite performance and free manufacturing engineers from the restraints of curing equipment size limitations. Recent efforts on a Phase II project by Cornerstone Research Group, Inc. (CRG), have advanced the technology and manufacturing readiness levels of a unique two-part epoxy resin system. Designed for room-temperature infusion of a dry carbon preform, the system includes a no-heat-added cure that delivers 350 F composite performance in a matter of hours. This no-oven, no-autoclave (NONA) composite processing eliminates part-size constraints imposed by infrastructure and lowers costs by increasing throughput and reducing capital-specific, process-flow bottlenecks. As a result of the Phase II activity, NONA materials and processes were used to make high-temperature composite tooling suitable for further production of carbon-epoxy laminates and honeycomb/ sandwich-structure composites with an aluminum core. The technology platform involves tooling design, resin infusion processing, composite part design, and resin chemistry. The various technology elements are combined to achieve a fully cured part. The individual elements are not unusual, but they are combined in such a way that enables proper management of the heat generated by the epoxy resin during cure. The result is a self-cured carbon/ epoxy composite part that is mechanically and chemically stable at temperatures up to 350 F. As a result of the successful SBIR effort, CRG has launched NONA Composites as a spinoff subsidiary. The company sells resin to end users, fabricates finished goods for customers, and sells composite tooling made with NONA materials and processes to composite manufacturers.

Rauscher, Michael D.↗

NASA NTRS2016

Airborne In-Situ Measurements of Formaldehyde Over California: First Results from the Compact Formaldehyde Fluorescence Experiment (COFFEE) Instrument

Formaldehyde (HCHO) is one of the most abundant oxygenated volatile organic compounds (VOCs) in the atmosphere, playing a role multiple atmospheric processes. Measurements of HCHO can be used to help quantify convective transport, the abundance of VOCs, and ozone production in urban environments. The Compact Formaldehyde FluorescencE Experiment (COFFEE) instrument uses Non-Resonant Laser Induced Fluorescence (NR-LIF) to detect trace concentrations of HCHO as part of the Alpha Jet Atmospheric eXperiment (AJAX) payload. Developed at NASA GSFC, COFFEE is a small, low maintenance instrument with a sensitivity of 100 pptv and a quick response time (1 sec). The COFFEE instrument has been customized to fit in an external wing pod on the Alpha Jet aircraft based at NASA ARC. The instrument can operate over a broad range of altitudes, from boundary layer to lower stratosphere, making it well suited for the Alpha Jet, which can access altitudes from the surface up to 40,000 ft. Results of the first COFFEE science flights preformed over the California's Central Valley will be presented. Boundary layer measurements and vertical profiles in the tropospheric column will both be included. This region is of particular interest, due to its elevated levels of HCHO, revealed in satellite images, as well as its high ozone concentrations. In addition to HCHO, the AJAX payload includes measurements of atmospheric ozone, methane, and carbon dioxide. Formaldehyde is one of the few urban pollutants that can be measured from space. Plans to compare in-situ COFFEE data with satellite-based HCHO observations such as those from OMI (Aura) and OMPS (SuomiNPP) will also be presented.

ozone↗

NASA NTRS2016

Heatshield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASAs high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50 mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in its 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

Thermal Protection System↗

NASA NTRS2016

Airborne In-Situ Measurements of Formaldehyde over California: First Results from the Compact Formaldehyde Fluorescence Experiment (COFFEE) Instrument

coffee↗

NASA NTRS2016

Heat-shield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASA's high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50% mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in it's 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to-date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

TPS↗

NASA NTRS2016

The Effects of Hygrothermal Aging on the Impact Penetration Resistance of Triaxially Braided Composites

An experimental study was conducted to measure the effects of long term hygrothermal aging on the impact penetration resistance of triaxially braided polymer composites. Flat panels of three different materials were subjected to repeated cycles of high and low temperature and high and low humidity for two years. Samples of the panels were periodically tested under impact loading during the two year time period. The purpose of the study was to identify and quantify any degradation in impact penetration resistance of these composites under cyclic temperature and humidity conditions experienced by materials in the fan section of commercial gas turbine engines for a representative aircraft flight cycle. The materials tested consisted of Toray ® T700S carbon fibers in a 2D triaxial braid with three different resins, Cycom® PR520, a toughened resin, Hercules® 3502, an untoughened resin and EPON 862, intermediate between the two. The fiber preforms consisted of a quasi-isotropic 0/+60/-60 braid with 24K tows in the axial direction and 12K tows in the bias directions. The composite panels were manufactured using a resin transfer molding process producing panels with a thickness of 0.125 inches. The materials were tested in their as-processed condition and again after one year and two years of aging (1.6 years in the case of E862). The aging process involved subjecting the test panels to two cycles per day of high and low temperature and high and low humidity. A temperature range of -60degF to 250degF and a humidity range of 0 to 85% rh was used to simulate extreme conditions for composite components in the fan section of a commercial gas turbine engine. Additional testing was conducted on the as-processed PR520 composite under cryogenic conditions. After aging there was some change in the failure pattern, but there was no reduction in impact penetration threshold for any of the three systems, and in the case of the 3502 system, a significant increase in penetration threshold. There was also an increase in the penetration resistance of the PR520 system impacted under cryogenic conditions.

composite↗

NASA NTRS2016

Influence of Constituents on Creep Properties of SiC/SiC Composites

SiC-SiC composites are being considered as potential candidate materials for next generation turbine components such as combustor liners, nozzle vanes and blades because of their low density, high temperature capability, and tailorable mechanical properties. These composites are essentially fabricated by infiltrating matrix into a stacked array of fibers or fiber preform by one or a combination of manufacturing methods such as, Melt Infiltration (MI) of molten silicon metal, Chemical Vapor Infiltration (CVI), Polymer Infiltration and Pyrolysis (PIP). To understand the influence of constituents, the SiC-SiC composites fabricated by MI, CVI, and PIP methods were creep tested in air between 12000 and 14500 degrees Centigrade for up to 500 hours. The failed specimens were analyzed under a scanning electron microscope to assess damage mechanisms. Also, knowing the creep deformation parameters of the fiber and the matrix under the testing conditions, the creep behavior of the composites was modeled and compared with the measured data. The implications of the results on the long term durability of these composites will be discussed.

modeling↗

NASA NTRS2017

Lightweight Multifunctional Planetary Probe for Extreme Environment Exploration and Locomotion

The demand to explore new worlds requires the development of advanced technologies that enable landed science on uncertain terrains or in hard to reach locations. As a result, contemporary Entry, Descent, Landing, (EDL) and additional locomotion (EDLL) profiles are becoming increasingly more complex, with the introduction of lifting/guided entries, hazard avoidance on descent, and a plethora of landing techniques including airbags and the skycrane maneuver. The inclusion of each of these subsystems into a mission profile is associated with a substantial mass penalty. This report explores the new all-in-one entry vehicle concept, TANDEM, a new combined EDLL concept, and compares it to the current state of the art EDL systems. The explored system is lightweight and collapsible and provides the capacity for lifting/guided entry, guided descent, hazard avoidance, omnidirectional impact protection and surface locomotion without the aid of any additional subsystems. This Phase I study explored: 1. The capabilities and feasibility of the TANDEM concept as an EDLL vehicle. 2. Extensive impact analysis to ensure mission success in unfavorable landing conditions, and safe landing in Tessera regions. 3. Development of a detailed design for a conceptual mission to Venus. As a result of our work it was shown that: 1. TANDEM provides additional benefits over the Adaptive, Deployable Entry Placement Technology (ADEPT) including guided descent and surface locomotion, while reducing the mass by 38% compared to the ADEPT-VITaL mission. 2. Demonstrated that the design of tensegrity structures, and TANDEM specifically, grows linearly with an increase in velocity, which was previously unknown. 3. Investigation of surface impact revealed a promising results that suggest a properly configured TANDEM vehicle can safely land and preform science in the Tessera regions, which was previously labeled by the Decadal Survey as, largely inaccessible despite its high scientific interest. This work has already resulted in a NASA TM and will be submitted to the Journal of Spacecraft and Rockets.

landing techniques↗

NASA NTRS2017

Radiative Heat Transfer Modeling in Fibrous Porous Media

Phenolic-Impregnated Carbon Ablator (PICA) was developed at NASA Ames Research Center as a lightweight thermal protection system material for successful atmospheric entries. The objective of the current work is to compute the effective radiative conductivity of fibrous porous media, such as preforms used to make PICA, to enable the efficient design of materials that can meet the thermal performance goals of forthcoming space exploration missions.

Radiative↗

NASA NTRS2017

Tortuosity Computations of Porous Materials using the Direct Simulation Monte Carlo

Low-density carbon fiber preforms, used as thermal protection systems (TPS) materials for planetary entry systems, have permeable, highly porous microstructures consisting of interlaced fibers. Internal gas transport in TPS is important in modeling the penetration of hot boundary-layer gases and the in-depth transport of pyrolysis and ablation products. The gas effective diffusion coefficient of a porous material must be known before the gas transport can be modeled in material response solvers; however, there are very little available data for rigid fibrous insulators used in heritage TPS.The tortuosity factor, which reflects the efficiency of the percolation paths, can be computed from the effective diffusion coefficient of a gas inside a porous material and is based on the micro-structure of the material. It is well known, that the tortuosity factor is a strong function of the Knudsen number. Due to the small characteristic scales of porous media used in TPS applications (typical pore size of the order of 50 micron), the transport of gases can occur in the rarefied and transitional regimes, at Knudsen numbers above 1. A proper way to model the gas dynamics at these conditions consists in solving the Boltzmann equation using particle-based methods that account for movement and collisions of atoms and molecules.In this work we adopt, for the first time, the Direct Simulation Monte Carlo (DSMC) method to compute the tortuosity factor of fibrous media in the rarefied regime. To enable realistic simulations of the actual transport of gases in the porous medium, digitized computational grids are obtained from X-ray micro-tomography imaging of real TPS materials. The SPARTA DSMC solver is used for simulations. Effective diffusion coefficients and tortuosity factors are obtained by computing the mean-square displacement of diffusing particles.We first apply the method to compute the tortuosity factors as a function of the Knudsen number for computationally designed materials such as random cylindrical fibers and packed bed of spheres with prescribed porosity. Results are compared to literature values obtained using random walk methods in the rarefied and transitional regime and a finite-volume method for the continuum regime. We then compute tortuosity factors for a real carbon fiber material with a transverse isotropic structure (FiberForm), quantifying differences between through-thickness and in-plain tortuosities at various Knudsen regimes.

Tortuosity↗

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 NTRS2018

Evaluation of Crew-Centric Onboard Mission Operations Planning and Execution Tool: Year 2

Currently, mission planning for the International Space Station (ISS) is largely affected by ground operators in mission control. The task of creating a week-long mission plan for ISS crew takes dozens of people multiple days to complete, and is often created far in advance of its execution. As such, re-planning or adapting to changing real-time constraints or emergent issues is similarly taxing. As we design for future mission operations concepts to other planets or areas with limited connectivity to Earth, more of these ground-based tasks will need to be handled autonomously by the crew onboard.There is a need for a highly usable (including low training time) tool that enables efficient self-scheduling and execution within a single package. The ISS Program has identified Playbook as a potential option. It already has high crew acceptance as a plan viewer from previous analogs and can now support a crew self-scheduling assessment on ISS or on another mission. The goals of this work, a collaboration between the Human Research Program and the ISS Program, are to inform the design of systems for more autonomous crew operations and provide a platform for research on crew autonomy for future deep space missions. Our second year of the research effort have included new insights on the crew self-scheduling sessions performed by the crew through use on the HERA (Human Exploration Research Analog) and NEEMO (NASA Extreme Environment Mission Operations) analogs. Use on the NEEMO analog involved two self-scheduling strategies where the crew planned and executed two days of EVAs (Extra-Vehicular Activities). On HERA year two represented the first HERA campaign where we were able to perform research tasks. This involved selected flexible activities that the crew could schedule, mock timelines where the crew completed more complex planning exercises, usability evaluation of the crew self-scheduling features, and more insights into the limit of plan complexity that the crew could effectively self-schedule. In parallel we have added in new features and functionality in the Playbook tool based off of our insights from crew self-scheduling in the NASA analogs. In particular this year we have added in the ability for the crew to add, edit, and remove their own activities in the Playbook tool, expanding the type of planning and re-planning possible in the tool and opening up the ability for more free form plan creation. The ability to group and manipulate groups of activities from the plan task list was also added, allowing crew members to add predefined sets of activities onto their mission timeline. In addition we also added a way for crew members to roll back changes in their plan, in order to allow an undo like capability. These features expand and complement the initial self-scheduling features added in year one with the goal of making crew autonomous planning more efficient. As part of this work we have also finished developing the first version of our Playbook Data Analysis Tool, a research tool built to interpret and analyze the unobtrusively collected data obtained during the NASA analog missions through Playbook. This data which includes user click interaction as well as plan change information, through the Playbook Data Analysis Tool, allows us to playback this information as if a video camera was mounted over the crewmember's tablet. While the primary purpose of this tool is to allow usability analysis of crew self-scheduling sessions used on the NASA analog, since the data collected is structured, the tool can automatically derive metrics that would be traditionally tedious to achieve without manual analysis of video playback. We will demonstrate and discuss the ability for future derived metrics to be added to the tool. In addition to the current data and results gathered in year two we will also discuss the preparation and goals of our International Space Station (ISS) onboard technology demonstration with Playbook. This technology demonstration will be preformed as part of the CAST payload starting in late 2016.

onboard planning↗

NASA NTRS2018

Sustaining PICA for Future NASA Robotic Science Missions Including NF-4 and Discovery

Phenolic Impregnated Carbon Ablator (PICA), invented in the mid 1990's, is a low-density ablative thermal protection material proven capable of meeting sample return mission needs from the moon, asteroids, comets and other unrestricted class V destinations as well as for Mars. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. It is important that NASA maintain this thermal protection material capability and ensure its availability for future NASA use. The rayon based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years and a third substitution is now needed. The carbon precursor replacement challenge is twofold - the first involves finding a long-term replacement for the current rayon and the second is to assess its future availability periodically to ensure it is sustainable and be alerted if additional replacement efforts need to be initiated. This paper reviews current PICA sustainability activities to identify a rayon replacement and to establish that the capability of the new PICA derived from an alternative precursor is in family with previous versions.

Stackpoole, Mairead↗