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At least 703 records · Page 39

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NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗

NASA NTRS1980

Thermal protection of reentry vehicles by actively cooled nosetips

Analytical modeling efforts and clear-air ground test results of a transportation-cooled nosetips (TCNT) design are presented. The discrete water injection platelet TCNT described was conceived and created to achieve the performance requirements for severe reentry vehicle trajectories. Thermal performance computer modeling techniques, combing both local heat blockage and boundary layer recovery enthalpy reduction are outlined.

Walker, R. E.↗

NASA NTRS1979

Industry tests of NASA ceramic thermal barrier coating

Ceramic thermal barrier coating (TBC) system was tested by industrial and governmental organizations for a variety of aeronautical, marine, and ground-based gas turbine engine applications. This TBC is a two-layer system with a bond coating of nickel-chromium-aluminum-yttrium (Ni-16Cr-6Al-0.6Y, in wt. percent) and a ceramic coating of yttria-stabilized zirconia (ZrO2-12Y2O3, in wt. percent). Seven tests evaluated the system's thermal protection and durability. Five other tests determined thermal conductivity, vibratory fatigue characteristics, and corrosion resistance of the system. The information presented includes test results and photographs of the coated parts. Recommendations are made for improving the coating procedures.

Liebert, C. H.↗

NASA NTRS1993

Degradation of electro-optic components aboard LDEF

Remeasurement of the properties of a set of electro-optic components exposed to the low-earth environment aboard the Long Duration Exposure Facility (LDEF) indicates that most components survived quite well. Typical components showed some effects related to the space environment unless well protected. The effects were often small but significant. Results for semiconductor infrared detectors, lasers, and LED's, as well as filters, mirrors, and black paints are described. Semiconductor detectors and emitters were scarred but reproduced their original characteristics. Spectral characteristics of multi-layer dielectric filters and mirrors were found to be altered and degraded. Increased absorption in black paints indicates an increase in absorption sites, giving rise to enhanced performance as coatings for baffles and sunscreens.

Blue, M. D.↗

NASA NTRS2007

Multilayer Impregnated Fibrous Thermal Insulation Tiles

The term "secondary polymer layered impregnated tile" ("SPLIT") denotes a type of ablative composite-material thermal- insulation tiles having engineered, spatially non-uniform compositions. The term "secondary" refers to the fact that each tile contains at least two polymer layers wherein endothermic reactions absorb considerable amounts of heat, thereby helping to prevent overheating of an underlying structure. These tiles were invented to afford lighter-weight alternatives to the reusable thermal-insulation materials heretofore variously used or considered for use in protecting the space shuttles and other spacecraft from intense atmospheric-entry heating.

Tran, Huy K.↗

NASA NTRS2009

Hypervelocity Impact Performance of Open Cell Foam Core Sandwich Panel Structures

Metallic foams are a relatively new class of materials with low density and novel physical, mechanical, thermal, electrical and acoustic properties. Although incompletely characterized, they offer comparable mechanical performance to traditional spacecraft structural materials (i.e. honeycomb sandwich panels) without detrimental through-thickness channeling cells. There are two competing types of metallic foams: open cell and closed cell. Open cell foams are considered the more promising technology due to their lower weight and higher degree of homogeneity. Leading micrometeoroid and orbital debris shields (MMOD) incorporate thin plates separated by a void space (i.e. Whipple shield). Inclusion of intermediate fabric layers, or multiple bumper plates have led to significant performance enhancements, yet these shields require additional non-ballistic mass for installation (fasteners, supports, etc.) that can consume up to 35% of the total shield weight [1]. Structural panels, such as open cell foam core sandwich panels, that are also capable of providing sufficient MMOD protection, represent a significant potential for increased efficiency in hypervelocity impact shielding from a systems perspective through a reduction in required non-ballistic mass. In this paper, the results of an extensive impact test program on aluminum foam core sandwich panels are reported. The effect of pore density, and core thickness on shielding performance have been evaluated over impact velocities ranging from 2.2 - 9.3 km/s at various angles. A number of additional tests on alternate sandwich panel configurations of comparable-weight have also been performed, including aluminum honeycomb sandwich panels (see Figure 1), Nomex honeycomb core sandwich panels, and 3D aluminum honeycomb sandwich panels. A total of 70 hypervelocity impact tests are reported, from which an empirical ballistic limit equation (BLE) has been derived. The BLE is in the standard form suitable for implementation in risk analysis software, and includes the effect of panel thickness, core density, and facesheet material properties. A comparison between the shielding performance of foam core sandwich panel structures and common MMOD shielding configurations is made for both conservative (additional 35% non-ballistic mass) and optimistic (additional mass equal to 30% of bumper mass) considerations. Suggestions to improve the shielding performance of foam core sandwich panels are made, including the use of outer mesh layers, intermediate fabric/composite layers, and varying pore density.

Ryan, Shannon↗

NASA NTRS2014

Exploring Mars for Evidence of Habitable Environments and Life

The climate of Mars has been more similar to that of Earth than has the climate of any other planet in our Solar System. But Mars still provides a valuable alternative example of how planetary processes and environments can affect the potential presence of life elsewhere. For example, although Mars also differentiated very early into a core, mantle and crust, it then evolved mostly if not completely without plate tectonics and has lost most of its early atmosphere. The Martian crust has been more stable than that of Earth, thus it has probably preserved a more complete record of its earliest history. Orbital observations determined that near-surface water was once pervasive. Orbiters have identified the following diverse aqueous sedimentary deposits: layered phyllosilicates, phyllosilicates in intracrater fans, plains sediments potentially harboring evaporitic minerals, deep phyllosilicates, carbonate-bearing deposits, intracrater clay-sulfate deposits, Meridiani-type layered deposits, valles-type layered deposits, hydrated silica-bearing deposits, and gypsum plains. These features, together with evidence of more vigorous past geologic activity, indicate that early climates were wetter and perhaps also somewhat warmer. The denser atmosphere that was required for liquid water to be stable on the surface also provided more substantial protection from radiation. Whereas ancient climates might have favored habitable environments at least in some localities, clearly much of the Martian surface for most of its history has been markedly less favorable for life. The combination of dry conditions, oxidizing surface environments and typically low rates of sedimentation are not conducive to the preservation of evidence of ancient environments and any biota. Thus a strategy is required whereby candidate sites are first identified and then characterized for their potential to preserve evidence of past habitable environments. Rovers are then sent to explore the most promising candidates. The Mars Exploration Rover (MER) Opportunity revealed that water once flowed to the surface across the vast Meridiani plains, creating saline lakes whose waters were roiled by ancient winds that also sculptured their salt deposits into sand dunes. Opportunity then drove more than 30 km to explore even older deposits on a crater rim. MER Spirit found evidence that thermal waters (heated by volcanism or by impacts?) altered rocks to create sulfate salts, and siliceous sinters. These discoveries indicate that an early hydrological cycle apparently sustained precipitation, streams and lakes. Liquid water participated in rock weathering reactions, such as iron and sulfur oxidation, that created distinctive weathering regimes. Volcanism, impacts, groundwater and ice interacted at least locally. Redox chemical energy from volcanism, hydrothermal activity and weathering of crustal materials would have been available for any life. Thus conditions might have supported life in the past, at least locally. The main objective of the Mars Science Laboratory (MSL) Curiosity rover is to determine the extent to which Gale crater hosted environments capable of supporting microbial life. The rover has already found stream gravels as well as sediments that might have been deposited in an ancient lake. The rover is now traversing to Mt. Sharp, a 5 km-high mound that is located on the crater floor and that exhibits layered sedimentary rocks having diverse minerals (sulfates and clays) that apparently formed in the presence of liquid water. This rock sequence was deposited over an extended time period in diverse potentially habitable watery environments. Curiosity is poised to characterize a a well-preserved rock record of hundreds of millions of years of diverse environments and profound climate change.

layered phyllosilicates↗

NASA NTRS1963

The solar cells and their mounting

Objectives in development of the solar plant for the Telstar spacecraft were to provide a power source which would withstand launching stresses and the expected space environment, with optimum end-of-life performance. Radiation damage to the silicon solar cells is the primary factor limiting their useful life; the effect of energetic protons or electrons is the generation of recombination centers in the silicon which reduce the minority-carrier diffusion length and therefore the long-wave response of the cell. The spacecraft solar cells use the n-on-p structure, in preference to conventional p-on-n structure, to obtain a factor of 3 to 10 increased life expectancy. Response to light in the 0.4 to 0.7 micron range is enhanced by using a thin n-layer (about 0.5 micron) and an antireflection coating with minimum reflectance at 0.55 micron wavelength. Early estimates of electron and proton fluxes in the satellite orbit showed that even the best cells would not give sufficient life without radiation shielding. Therefore the cells are protected against electrons of energy up to 1 Mev by 0.3 gm/sq. cm sapphire cover plates. The cell mountings are designed to withstand peak vibration stresses of 200 g and repeated temperature cycles from +65°C to −100°C. The 3600-cell solar power plant is composed of 300 twelve-cell groups of 1 cm × 2 cm cells, yielding a nominal initial power of 14 watts at 28 volts for any spin-axis orientation relative to the sun. Telemetry information on performance of the solar plant indicates degradation of the shielded solar cells equal to that measured in the laboratory on unshielded cells with a 1-Mev normal incidence flux of 6 × 10^(12) electrons/(sq. cm day). From this comparison it is estimated that the plant will degrade to 68 per cent of its initial output after two years in orbit.

SPACECRAFT POWER SUPPLY↗

NASA NTRS1976

Coatings for directional eutectics

Coatings developed to provide oxidation protection for the directionally-solidified eutectic alloy NiTaC-B (4.4 weight percent Cr) were evaluated. Of seven Co-, Fe- and Ni-base coatings that were initially investigated, best resistance to cyclic oxidation was demonstrated by duplex coatings fabricated by depositing a layer of NiCrAl(Y) by vacuum evaporation from an electron beam source followed by deposition of an Al overlayer using the pack cementation process. It was found that addition of carbon to the coating alloy substantially eliminated the problem of fiber denudation in TaC-type eutectic alloys. Burner rig cycled NiTaC-B samples coated with Ni-20Cr-5Al-0.1C-0.1Y+Al and rupture-tested at 1100 deg C performed as well as or better than uncoated, vacuum cycled and air-tested NiTaC-13; however, a slight degradation with respect to uncoated material was noted in air-stress rupture tests at 870 deg C for both cycled and uncycled samples.

Rairden, J. R.↗

NASA NTRS1997

Hypersonic Flight Experimentation - Status and Shortfalls

For some 50 years, man has flown, very successfully, in and through the hypersonic flow regime up to Mach Number 35 and beyond with very few "surprises." In general, hypersonic vehicles have performed successfully with good-to-excellent comparisons between flight, ground facility extrapolations and computations being the norm. A consistent and glaring shortfall to date is in the boundary layer transition arena, due primarily to the dominance for flight vehicles of roughness induced transition where the roughness characteristics are extremely vehicle specific and dictated by either vehicle operational exigencies such as antennas, handling plugs, and field joints, etc. or characteristics of the thermal protection system. Emerging shortfalls for future systems which require research flight tests include transition and air-breathing propulsion-related technology for both cruise and space access. Specific flight test recommendations include "systems demonstrations" for various air-breathing propulsion options and efforts to correct a pervasive lack of adequate analysis of the existing, and very expensive to replicate, hypersonic flight data base.

Bushnell, Dennis M.↗

NASA NTRS2002

Rocket Motor Joint Construction Including Thermal Barrier

A thermal barrier for extremely high temperature applications consists of a carbon fiber core and one or more layers of braided carbon fibers surrounding the core. The thermal barrier is preferably a large diameter ring, having a relatively small cross-section. The thermal barrier is particularly suited for use as part of a joint structure in solid rocket motor casings to protect low temperature elements such as the primary and secondary elastomeric O-ring seals therein from high temperature gases of the rocket motor. The thermal barrier exhibits adequate porosity to allow pressure to reach the radially outward disposed O-ring seals allowing them to seat and perform the primary sealing function. The thermal barrier is disposed in a cavity or groove in the casing joint, between the hot propulsion gases interior of the rocket motor and primary and secondary O-ring seals. The characteristics of the thermal barrier may be enhanced in different applications by the inclusion of certain compounds in the casing joint, by the inclusion of RTV sealant or similar materials at the site of the thermal barrier, and/or by the incorporation of a metal core or plurality of metal braids within the carbon braid in the thermal barrier structure.

Steinetz, Bruce M.↗

NASA NTRS2011

Access Control of Web and Java Based Applications

Cyber security has gained national and international attention as a result of near continuous headlines from financial institutions, retail stores, government offices and universities reporting compromised systems and stolen data. Concerns continue to rise as threats of service interruption, and spreading of viruses become ever more prevalent and serious. Controlling access to application layer resources is a critical component in a layered security solution that includes encryption, firewalls, virtual private networks, antivirus, and intrusion detection. In this paper we discuss the development of an application-level access control solution, based on an open-source access manager augmented with custom software components, to provide protection to both Web-based and Java-based client and server applications.

cybersecurity↗

NASA NTRSDate not supplied

LOFTID Surface Heating Reconstruction

On November 10, 2022, the Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) reentry vehicle launched to low-Earth orbit aboard a United Launch Alliance Atlas V rocket out of Vandenberg Air Force Base. The aeroshell, the largest Hypersonic Inflatable Aerodynamic Decelerator (HIAD) ever flown, was inflated to its full 6-meter diameter before successful re-entry into the atmosphere. The aeroshell was heavily instrumented in order to understand its behavior during entry. There were 82 thermocouples (TCs) distributed across the aeroshell, with 22 integrated into the flexible thermal protection system (FTPS) on the rigid nose, 36 in the FTPS on the deployable structure, and 24 on the inflatable structure. TCs were placed at different depths throughout the FTPS. Those nearest to the surface were located just beneath the two SiC outer fabric layers. The near-surface TCs on the rigid nose were Type R with flame spray alumina insulation, while those on the flank were Type N with mica/ceramic insulation. Additionally, a radiometer was placed at the center of the nose surrounded by four total heat flux gauges in a cruciform configuration at a radius of 0.41 m. The nose instrumentation is shown in Fig. 1 and a cross-section of the aeroshell with all TC locations is shown in Fig. 2. The objective of this work was to use the temperatures measured by the TCs during flight to estimate the surface heat rate across the aeroshell throughout the period of re-entry by inverse analysis methodology. The results were used to evaluate the fidelity of measurements from the total heat flux gauges on the nose, determine the surface heat flux at aeroshell locations where gauges were not present, and compare to pre-flight CFD-based heating predictions. Inversely estimated surface heat flux continues to be used to correlate FTPS thermal models to reconstruct in-flight thermal response.

H S Alpert↗

NASA NTRSDate not supplied

LOFTID Surface Heating Reconstruction

LOFTID↗

NASA NTRS2003

Polar and Non-Polar Layers on Mars: A Single Mechanism for Formation?

The recent discovery of vast quantities of near-subsurface ice in both polar regions of Mars by the Mars Odyssey Gamma Ray Spectrometer (GRS) has presented us with an interesting quandary. On one hand, these deposits, found poleward of 60 deg in both hemispheres, are consistent with thermal models suggesting ice will be best protected in these regions during periods of high obliquity. On the other hand, the current paradigm regarding the placement of these deposits, i.e., diffusive deposition of water vapor, appears to be inconsistent with the large volume mixing ratios (approx. 90%) inferred from the GRS data. This incongruity argues that diffusion alone cannot be the primary mechanism for the creation of these reservoirs, and that an alternate, large-scale process should be considered.

Mischna, M. A.↗

NASA NTRS1997

Investigation of Teflon FEP Embrittlement on Spacecraft in Low Earth Orbit

Teflon(registered trademark) FEP (fluorinated ethylene-propylene) is commonly used on exterior spacecraft surfaces in the low Earth orbit (LEO) environment for thermal control. Silverized or aluminized FEP is used for the outer layer of thermal control blankets because of its low solar absorptance and high thermal emittance. FEP is also preferred over other spacecraft polymers because of its relatively high resistance to atomic oxygen erosion. Because of its low atomic oxygen erosion yield, FEP has not been protected in the space environment. Recent, long term space exposures such as on the Long Duration Exposure Facility (LDEF, 5.8 years in space), and the Hubble Space Telescope (HST, after 3.6 years in space) have provided evidence of LEO environmental degradation of FEP. These exposures provide unique opportunities for studying environmental degradation because of the long durations and the different conditions (such as differences in altitude) of the exposures. Samples of FEP from LDEF and from HST (retrieved during its first servicing mission) have been evaluated for solar induced embrittlement and for synergistic effects of solar degradation and atomic oxygen. Micro-indenter results indicate that the surface hardness increased as the ratio of atomic oxygen fluence to solar fluence decreased for the LDEF samples. FEP multilayer insulation (MLI) retrieved from HST provided evidence of severe embrittlement on solar facing surfaces. Micro-indenter measurements indicated higher surface hardness values for these samples than LDEF samples, but the solar exposures were higher. Cracks induced during bend testing were significantly deeper for the HST samples with the highest solar exposure than for LDEF samples with similar atomic oxygen fluence to solar fluence ratios. If solar fluences are compared, the LDEF samples appear as damaged as HST samples, except that HST had deeper induced cracks. The results illustrate difficulties in comparing LEO exposed materials from different missions. Because the HST FEP appears more damaged than LDEF FEP based on depth of embrittlement, other causes for FEP embrittlement in addition to atomic oxygen and ultraviolet (UV) radiation, such as thermal effects and the possible role of soft x-ray radiation, need to be considered. FEP that was exposed to soft x-rays in a ground test facility, showed embrittlement similar to that witnessed in LEO, which indicates that the observed differences between LDEF and HST FEP might be attributed to the different soft x-ray fluences during these two missions.

deGroh, Kim K.↗

NASA NTRS2002

Thermal Barrier/Seal for Extreme Temperature Applications

Large solid rocket motors, as found on the Space Shuttle, are fabricated in segments for manufacturing considerations, bolted together, and sealed using conventional Viton O-ring seals. Similarly the nine large solid rocket motor nozzles are assembled from several different segments, bolted together, and sealed at six joint locations using conventional O-ring seals. The 5500 F combustion gases are generally kept a safe distance away from the seals by thick layers of phenolic or rubber insulation. Joint-fill compounds, including RTV (room temperature vulcanized compound) and polysulfide filler, are used to fill the joints in the insulation to prevent a direct flow-path to the O-rings. Normally these two stages of protection are enough to prevent a direct flow-path of the 900-psi hot gases from reaching the temperature-sensitive O-ring seals. However, in the current design 1 out of 15 Space Shuttle solid rocket motors experience hot gas effects on the Joint 6 wiper (sacrificial) O-rings. Also worrisome is the fact that joints have experienced heat effects on materials between the RTV and the O-rings, and in two cases O-rings have experienced heat effects. These conditions lead to extensive reviews of the post-flight conditions as part of the effort to monitor flight safety. We have developed a braided carbon fiber thermal barrier to replace the joint fill compounds in the Space Shuttle solid rocket motor nozzles to reduce the incoming 5500 F combustion gas temperature and permit only cool (approximately 100 F) gas to reach the temperature-sensitive O-ring seals. Implementation of this thermal barrier provides more robust, consistent operation with shorter turn around times between Shuttle launches.

Steinetz, Bruce M.↗

NASA NTRS2009

Retro Rocket Motor Self-Penetrating Scheme for Heat Shield Exhaust Ports

A preliminary scheme was developed for base-mounted solid-propellant retro rocket motors to self-penetrate the Orion Crew Module heat shield for configurations with the heat shield retained during landings on Earth. In this system the motors propel impactors into structural push plates, which in turn push through the heat shield ablator material. The push plates are sized such that the remaining port in the ablator material is large enough to provide adequate flow area for the motor exhaust plume. The push plate thickness is sized to assure structural integrity behind the ablative thermal protection material. The concept feasibility was demonstrated and the performance was characterized using a gas gun to launch representative impactors into heat shield targets with push plates. The tests were conducted using targets equipped with Fiberform(R) and PICA as the heat shield ablator material layer. The PICA penetration event times were estimated to be under 30 ms from the start of motor ignition. The mass of the system (not including motors) was estimated to be less than 2.3 kg (5 lbs) per motor. The configuration and demonstrations are discussed.

landing system↗