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NASA NTRS1984

A new concept for a Titan atmospheric probe

Since the Voyager 1 close-pass observations of Titan, scientific interest in the nature and composition of the atmosphere and surface of Titan has increased greatly. This enhanced interest has led to the study of mission options to the Saturnian system with a principal goal of depositing a probe into the atmosphere of Titan. Such a probe could carry instrumentation to perform in situ measurements of the structure and composition of the atmosphere and clouds and of the morphology and composition of the surface. Previous studies have examined the possibility of modifying, in a minimal way, the Galileo probe currently being prepared for an atmospheric sampling mission to Jupiter. The purpose of this paper is to report the results of a study of probe-system concepts optimized for the Titan mission. The scientific rationale for such a mission to Titan is discussed and instruments to accomplish the scientific goals are indicated. Probe systems compatible with those goals and instruments are described, and the associated development costs for each are discussed.

Swenson, B. L.↗

NASA NTRS2018

A Common Probe Design for Multiple Planetary Destinations

Atmospheric probes have been successfully flown to planets and moons in the solar system to conduct in situ measurements. They include the Pioneer Venus multi-probes, the Galileo Jupiter probe, and Huygens probe. Probe mission concepts to five destinations, including Venus, Jupiter, Saturn, Uranus, and Neptune, have all utilized similar-shaped aeroshells and concept of operations, namely a 45-degree sphere cone shape with high density heatshield material and parachute system for extracting the descent vehicle from the aeroshell. Each concept designed its probe to meet specific mission requirements and to optimize mass, volume, and cost. At the 2017 International Planetary Probe Workshop (IPPW), NASA Headquarters postulated that a common aeroshell design could be used successfully for multiple destinations and missions. This "common probe" design could even be assembled with multiple copies, properly stored, and made available for future NASA missions, potentially realizing savings in cost and schedule and reducing the risk of losing technologies and skills difficult to sustain over decades. Thus the NASA Planetary Science Division funded a study to investigate whether a common probe design could meet most, if not all, mission needs to the five planetary destinations with extreme entry environments. The Common Probe study involved four NASA Centers and addressed these issues, including constraints and inefficiencies that occur in specifying a common design. Study methodology: First, a notional payload of instruments for each destination was defined based on priority measurements from the Planetary Science Decadal Survey. Steep and shallow entry flight path angles (EFPA) were defined for each planet based on qualification and operational g-load limits for current, state-of-the-art instruments. Interplanetary trajectories were then identified for a bounding range of EFPA. Next, 3-degrees-of-freedom simulations for entry trajectories were run using the entry state vectors from the interplanetary trajectories. Aeroheating correlations were used to generate stagnation point convective and radiative heat flux profiles for several aeroshell shapes and entry masses. High fidelity thermal response models for various Thermal Protection System (TPS) materials were used to size stagnation-point thicknesses, with margins based on previous studies. Backshell TPS masses were assumed based on scaled heat fluxes from the heatshield and also from previous mission concepts. Presentation: We will present an overview of the study scope, highlights of the trade studies and design driver analyses, and the final recommendations of a common probe design and assembly. We will also indicate limitations that the common probe design may have for the different destinations. Finally, recommended qualification approaches for missions will be presented.

Hwang, H. H.↗

NASA NTRS2018

A Common Probe Design for Multiple Planetary Destinations

Atmospheric probes have been successfully flown to planets and moons in the solar system to conduct in-situ measurements. They include the Pioneer Venus multi-probes, the Galileo Jupiter probe, and Huygens probe. Probe mission concepts to five destinations, including Venus, Jupiter, Saturn, Uranus, and Neptune, have all utilized similar-shaped aeroshells and concept of operations, namely a 45 deg sphere cone shape with high density heatshield material and parachute system for extracting the descent vehicle from the aeroshell. Each concept designed its probe to meet specific mission requirements and to optimize mass, volume, and cost. At the 2017 IPPW, NASA Headquarters postulated that a common aero-shell design could be used successfully for multiple destinations and missions. This "common probe" design could even be assembled with multiple copies, properly stored, and made available for future NASA missions, potentially realizing savings in cost and schedule and reducing the risk of losing technologies and skills difficult to sustain over decades. Thus the NASA Planetary Science Division funded a study to investigate whether a common probe design could meet most, if not all, mission needs to the five planetary destinations with extreme entry environments. The Common Probe study involved four NASA Centers and addressed these issues, including constraints and inefficiencies that occur in specifying a common design.Study methodology: First, a notional payload of instruments for each destination was defined based on priority measurements from the Planetary Science Decadal Survey. Steep and shallow entry flight path angles (EFPA) were defined for each planet based on qualification and operational g-load limits for current, state-of-the-art instruments. Interplanetary trajectories were then identified for a bounding range of EFPA. Next, 3-DoF simulations for entry trajectories were run using the entry state vectors from the interplanetary trajectories. Aeroheating correlations were used to generate stagnation point convective and radiative heat flux profiles for several aeroshell shapes and entry masses. High fidelity thermal response models for various TPS materials were used to size stagnation point thicknesses, with margins based on previous studies. Backshell TPS masses were assumed based on scaled heat fluxes from the heatshield and also from previous mission concepts.

Hwang, Helen H.↗

NASA NTRS2018

A Common Probe Design for Multiple Planetary Destinations

Introduction: Atmospheric probes have been successfully flown to planets and moons in the solar system to conduct in situ measurements. They include the Pioneer Venus multiprobes, the Galileo Jupiter probe, and Huygens probe. Probe mission concepts to five destinations, including Venus, Jupiter, Saturn, Uranus, and Neptune, have all utilized similarshaped aeroshells and concept of operations, namely a 45° sphere cone shape with high density heatshield material and parachute system for extracting the descent vehicle from the aeroshell. The current paradigm is to design a probe to meet specific mission requirements and to optimize mass, volume, and cost for a single mission. However, this methodology means repeated efforts to design an aeroshell for different destinations with minor differences. A new paradigm has been explored that has a "common probe" design that could be flown at these different destinations and could be assembled in advance with multiple copies, properly stored, and made available for future NASA missions.

Hwang, Helen H.↗

NASA NTRS2018

A Common Probe Design for Multiple Planetary Destinations

Hwang, Helen H.↗

NASA NTRSDate not supplied

Trajectory Engineering with Modular Patched Conics for Entry Systems and TPS (TEMPEST)

Brief Presenter Biography (35 word limit): Bohdan Wesely is an Aerospace Engineer in the Entry Systems and Technology Division at Ames. He has worked on a variety of projects for NASA including integrated TPS (thermal protection system) flight hardware deliveries and testing services for commercial partners. Introduction: TEMPEST is a new trajectory analysis framework that is designed to fill the gap between dedicated flight mechanics tools and aerothermal and TPS sizing tools. The project started as an SJSU master’s thesis and has since evolved into a general conceptual design tool capable of studying a wide variety of entry problems. Development is ongoing in the Entry Systems and Technology Division at NASA ARC. Why TEMPEST: Space missions involving entry into a planetary atmosphere involve a series of unique requirements across multiple disciplines. Whether it is traditional entry descent and landing (EDL), or aerocapture, the vehicle must navigate to its target landing location or orbit state, and the TPS must protect the payload during entry. The design process typically involves iterative handoffs between various flight mechanics, flow solver, and material response level tools. During the early conceptual phase, a wide variety of feasible trajectories are simulated in a Monte Carlo scenario which broadly satisfy the mission or landing requirements. Next, computational fluid dynamics (CFD), direct simulation Monte Carlo (DSMC), and other flow solver analyses are performed at various key trajectory points to generate an aero-database, heating and TPS design requirements also emerge at this stage. At this point, with updated aerodynamics from the various flow solvers, trajectories can be re-run, this in turn can change the required freestream conditions for the CFD tools, and as a project progresses, these analyses converge, and uncertainty is reduced. However, there is always a “hand-off” occurring between two inherently coupled phenomena. Analysis Description: One of the goals with TEMPEST is to use a variety of first principles estimation methods coupled with an atmosphere model to predict vehicle aerothermodynamics across the entire flight regime while propagating a 3 or 6 degree of freedom (DoF) trajectory. Aerodynamics methods include modified Newtonian, Maxwell and Cercignani- Lampis-Lord (CLL) for continuum, transitional, and free molecular flow regimes. Aerothermodynamics include boundary layer and reference enthalpy methods, and Mutation++ for non-equilibrium chemistry modeling. TEMPEST is also capable of stitching multiple trajectory segments together to study mission scenarios like multi-pass aerocapture and aero-gravity assists. Most of the program is implemented in MATLAB using modern system objects, it relies on several C++ shared libraries for supporting tools like Gmsh, the Global Reference Atmospheric Model (GRAM), and Mutation++. The various first principles aerothermal estimation methods are discretized across either a structured axisymmetric panel mesh or an unstructured tri-mesh generated from an open-source tool such as Gmsh, this allows solutions on the same mesh to be compared across tools such as CB-Aero. CFD Coupling. A physics-aware, gaussian process CFD anchoring scheme is proposed to adjust the various first principles methods as a CFD database is populated. One goal for this anchoring module is to inform the project where CFD should be run. Full knowledge of the entire trajectory, atmosphere, and aerothermodynamics allows for easier identification of high sensitivity areas and uncertainty quantification. While the first principles effects are well known and proven accurate in existing tools such as CB- Aero and Cart3D, a physics aware CFD anchoring scheme increases tool credibility across a project lifecycle. Material Response Modeling. Correct TPS sizing is critical for optimizing mass for science payloads and ensuring mission success. The process typically involves a thermal analysis along the trajectory with surface heating environments as a boundary condition. Several design constraints are maximum bondline temperature and maximum recession with various margining techniques. The material response tool FIAT, developed out of NASA Ames, is currently being integrated into the TEMPEST environment. TPS recession, shape change, mass loss, and mass property alteration are all factors that can perturb an entry trajectory. For missions like Mars 2020, recession was minimal and was safely handled separately as a post process. For missions such as Jupiter Galileo with a high TPS mass fraction or asteroid entries, recession plays a major role. The proposed fully coupled scheme is to use an epoch-based approach where the trajectory integration is halted after a recession threshold, the energy balance and FIAT are solved at each panel, the mesh, aerodynamics, and mass properties are updated, and the trajectory continues. Several computational tradeoffs have been made during the development of TEMPEST to limit the cost of a single trajectory and preserve its utility as a conceptual, rapid iteration tool. Conclusion: Development of TEMPEST is ongoing and the project is still in its infancy. This talk aims to showcase its unique capabilities to support future NASA entry systems missions.

Bohdan O Wesely↗

NASA NTRS2019

Exploration of Atmospheric Entries at Uranus & Neptune with HEEET as Heatshield TPS

One important observation from the recent Ice Giants Study sponsored by NASA was that the predicted and margined thicknesses of HEEET (new NASA TPS technology) were much greater than could be woven with the currently established loom capabilities. Since the cost of a loom upgrade would be substantial, the present work explores the entry trajectory space to determine what combinations of entry parameters would result in HEEET thicknesses that fit within the existing loom infrastructure. Toward this end, the entry trajectory space, parameterized by ballistic coefficient and entry flight path angle, was systematically explored for 45° sphere-cone geometries of 3 different radii 0.2 m, 0.3 m, and 0.4 m which covered the range from Galileo-derived probes considered in the Ice Giants Study, and a follow-on study on the possibility of using a single probe architecture (in terms of size and mass) for various destinations, including Venus, Saturn, Uranus, and Neptune. The entry velocities, latitudes, and azimuths at Uranus and Neptune used in the present work were taken from the Ice Giants Study. For each 3D OF trajectory generated by a NASA Ames in-house code, TRAJ, the material response and thickness were computed using another NASA Ames code, FIAT, along with a margins policy proposed by the HEEET project. In the present work, ballistic coefficients ranging from 200 kg/sqm to 350 kg/sqm were considered along with entry flight path angles ranging from -16° to -36° (primarily to allow deceleration loads to vary between 50 g and 200 g).

Prabhu, Dinesh K.↗

NASA NTRS2019

Exploration of Atmospheric Entries at Uranus & Neptune with HEEET as Heatshield TPS

One important observation from the Ice Giants Study was that the predicted and margined thicknesses of HEEET were greater than could be woven with the currently established loom capabilities. Since the cost of a loom upgrade would be substantial, the present work explored the entry trajectory space to determine what combinations of entry parameters would result in HEEET thicknesses that fit within the existing loom infrastructure. Toward this end, the entry trajectory space, parameterized by ballistic coefficient and entry flight path angle, was systematically explored for 45° sphere-cone geometries of 3 different radii – 0.2 m, 0.3 m, and 0.4 m – which covered the range from Galileo-derived probes considered in the Ice Giants Study, and a follow-on study [4] on the possibility of using a single probe architecture (in terms of size and mass) for various destinations, including Venus, Saturn, Uranus, and Neptune. The entry velocities, latitudes, and azimuths at Uranus and Neptune used in the present work were taken from the Ice Giants Study [1]. For each 3DOF trajectory generated by a NASA Ames in-house code, TRAJ [5], the material response and thickness were computed using another NASA Ames code, FIAT [6], along with a margins policy proposed by the HEEET project [7]. In the present work, ballistic coefficients ranging from 200 kg/m2 to 350 kg/m2 were considered along with entry flight path angles ranging from -16° to -36° (primarily to allow deceleration loads to vary between 50 g and 200 g).

HEEET↗

NASA NTRS1996

Knowledge Acquisition, Validation, and Maintenance in a Planning System for Automated Image Processing

A key obstacle hampering fielding of AI planning applications is the considerable expense of developing, verifying, updating, and maintainting the planning knowledge base (KB). Planning systems must be able to compare favorably in terms of software lifecycle costs to other means of automation such as scripts or rule-based expert systems. This paper describes a planning application of automated imaging processing and our overall approach to knowledge acquisition for this application.

artificial intelligence image processing knowledge↗

NASA NTRS1993

Techniques and software for optimum and efficient mission science sequence development

Highly successful mission operations require efficient and cost-effective science sequence development. Of key importance is the Science Planning and Operations Team's (SPOT's) ability to complete science observation design and integration early in the sequence development process (i.e., before the sequence enters into a formal change control process). Once under formal change control, careful change paper documentation, Flight Team checks, and mission software checks make sequence changes more labor-intensive. This paper discusses team organization, strategies, scheduling, and software employed by the Voyager and Galileo SPOT's to complete science observation design and integration early in the sequence development process.

Bliss, David A.↗

NASA NTRS2019

Ballistic Entries for Saturn, Uranus, and Neptune with HEEET TPS

One important observation from the Ice Giants Study was that the predicted and margined thicknesses of HEEET were greater than could be woven with the currently established loom capabilities. Since the cost of a loom upgrade could be substantial and time consuming, the present work explored the entry trajectory space to determine what combinations of entry parameters would result in HEEET thicknesses that fit within the existing loom infrastructure. Toward this end, the entry trajectory space, parameterized by ballistic coefficient and entry flight path angle, was systematically explored for 45° sphere-cone geometries of 3 different radii – 0.2 m, 0.3 m, and 0.4 m – which covered the range from Galileo-derived probes considered in the Ice Giants Study, and a follow-on study on the possibility of using a single probe architecture (in terms of size and mass) for various destinations, including Venus, Saturn, Uranus, and Neptune. The entry velocities, latitudes, and azimuths at Uranus and Neptune used in the present work were taken from the Ice Giants Study. For each 3DOF trajectory generated by a NASA Ames in-house code, TRAJ, the material response and thickness were computed using another NASA Ames code, FIAT, along with a margins policy proposed by the HEEET project. In the present work, ballistic coefficients ranging from 200 kg/sq m to 350 kg/sq m were considered along with entry flight path angles ranging from -16° to -36° (primarily to allow deceleration loads to vary between 50 g and 200 g).

Atmospheric Entry↗

NASA NTRS2019

The Space Communications and Navigation Testbed aboard International Space Station: Seven Years of Space-based Reconfigurable Software Defined Communications, Navigation, and Networking

The adoption of software defined radios offers space missions a new way to develop and operate space transceivers for communications and navigation.The SCaN Testbed on-board the ISS led groundbreaking efforts to champion use of software defined radios for space communications. The SCaN Testbed has allowed NASA, industry, academia, and international partners to pursue their respective interests in joint collaboration with NASA, and move this technology and it's applications to the space domain. Launched in 2012, The SCaN Testbed has logged over 4000 hours of operation exploring the development, reconfiguration, and operation of software defined radios and their software applications. Over the past seven years, experimenters and organizations from across the United States and around the world, have advanced the applications of software defined radios and networks using the SCaN Tested. Some of SCaN Testbed's successful experiments include the demonstration of the first Ka-band full duplex space transceiver, which became an R&D 100 award winning technology, and was inducted into the Space Technology Hall of Fame, following the launch and space deployment of a successful commercial product line based on the Testbed radios.Experiments have focused on new software development and operations concepts for understanding how to manage and apply this relatively new technology to space to improve communications and navigation for space science and exploration missions. The advanced capabilities of the software radios allow for multiple applications or functions (e.g., communication and navigation) to operate from the same radio platform. Multiple software waveform applications enable software component reuse and improve efficiency for multiple applications operating over different mission phases. The new capabilities of software defined radios such as on-orbit reconfiguration, also present new challenges such as increased operational complexity. Experiments of the SCaN testbed include more intelligent or cognitive applications to improve communications efficiency and manage the complexity of the radios, the communication channels, and the network itself. The software defined radios on the SCaN Testbed are each compliant to NASA's Space Telecommunications Radio System (STRS) Architecture. The STRS Architecture provides commonality among radio developments from different providers and different mission applications, and is designed to reduce the cost, risk, and complexity of unique and custom radio developments. This radio architecture standard defines common waveform software interfaces, methods of instantiation, operation, and documentation. As the SCaN Testbed concludes its operations on ISS, this presentation explores the advancements and accomplishments made to advance software defined radio technology and its applications for exploration. The accomplishments cover a number of experiment areas in Ka-band and S-band communications with TDRS, high rate communications, adaptive waveform operation, navigation using both GPA and Galileo constellations, complex networking and disruptive tolerant link protocols, user initiative service, and initial experiments with intelligent and cognitive applications which demonstrate the significant potential of software defined and cognitive radios.

Mortensen, Dale↗

NASA NTRS1995

Noncausal telemetry data recovery techniques

Cost efficiency is becoming a major driver in future space missions. Because of the constraints on total cost, including design, implementation, and operation, future spacecraft are limited in terms of their size power and complexity. Consequently, it is expected that future missions will operate on marginal space-to-ground communication links that, in turn, can pose an additional risk on the successful scientific data return of these missions. For low data-rate and low downlink-margin missions, the buffering of the telemetry signal for further signal processing to improve data return is a possible strategy; it has been adopted for the Galileo S-band mission. This article describes techniques used for postprocessing of buffered telemetry signal segments (called gaps) to recover data lost during acquisition and resynchronization. Two methods, one for a closed-loop and the other one for an open-loop configuration, are discussed in this article. Both of them can be used in either forward or backward processing of signal segments, depending on where a gap is specifically situated in a pass.

Tsou, H.↗

NASA NTRSDate not supplied

Multiple Probe Measurements at Uranus Motivated By Spatial Variability

Motivation: Spatial variations in the temperature field and composition of Uranus' atmosphere demonstrate a need for multiple entry probes to characterize vertical profiles in multiple locations. We will review variation of composition and temperature, which are produced by dynamical processes on a range of scales from global (polar anomalies, zonal bands) to regional (vortices, storms) [1–2]. In particular, the spatial variation of convective activity is not well understood based on existing remote sensing observations [3]. Understanding how these processes operate, and how they modulate variable composition, is key to constraining bulk atmospheric abundances. Abundances in turn provide cosmochemical constraints on planetary origins. Secondary probes at Uranus: Key measurements for secondary probes are temperature-pressure profiles, along with compositional profiles. Radio occultations are limited to shallow levels less than ~2 bar [4]. In situ temperature-pressure measurements (or atmospheric structure measurements) can unambiguously extend these results to deeper levels. Measurements with vertical resolution of at least 2 km are needed to characterize anomalies like the 1.2-bar feature from the Voyager 2 occultation at 2–6° S [4], which supports a range of temperature gradients depending on assumptions of composition. Simultaneous measurements of temperature, pressure, and composition are key to understanding this class of features. Species such as methane, hydrogen sulfide, and ammonia must be measured along a probe descent profile because they vary over several orders of magnitude due to the strong temperature dependence of their saturation vapor pressures [e.g., 5]. Results of these measurements can be interpreted to understand the potential for moist convective activity in the atmosphere. Lessons from the other giant planets: On Jupiter, the Galileo Probe's entry into a meteorologically distinct five-micron hot spot led many to interpret the local composition as column-stretched, so that well-mixed abundances were reached at deeper levels than in surrounding, unperturbed regions [6–8]. Ground-based microwave measurements and Juno data now indicate that the deep depletion of ammonia is a very widespread atmospheric characteristic not limited to 5-µm hot spots [9–11]. But in the absence of multiple probes, we do not know if the other volatiles H2S and H2O behave in the same way. The open questions for the Jupiter case strongly motivate sending multiple probes to Uranus. On Saturn, retrievals of NH3 and PH3 abundances at shallow levels vary with latitude [12], but it is unknown how deep these differences extend, which is why a Saturn probe (or probes) was a mission theme for NASA's New Frontiers 4 and 5 opportunities [13]. Challenges for secondary probes: Cost is an issue due to the perception that it involves sacrifices to other mission elements. Spacecraft trajectories may be constrained by needs for orbit insertion that limit probe deliveries to different latitudes, and additional limitations may be placed on communication windows for probe descent phases (particularly if multiple probes are released from the orbiter simultaneously) [14]. Finally, composition sensors for miniature secondary probes are not at the required technological maturity [15]. Mass spectrometers are typically too large, massive, and powerhungry, while smaller nanosensors are only beginning to be developed for planetary missions. Finally, the need for probe survival heating is most easily met by radioisotope heat sources, but these require regulatory approvals that are even more difficult to satisfy compared to standard environmental reviews [16], unless the secondary probe is designed as a core element of a mission. References: [1] Molter E.M., et al. (2021) PSJ, 2, 3. [2] Rowe-Gurney N., et al. (2021) Icar, 365, 114506. [3] Hueso R., Sánchez-Lavega A. (2019) SSRv, 215, 52. [4] Lindal G.F., et al. (1987) JGR, 92, 14987– 15001. [5] Simon A.A., et al. (2022) RemS, 14, 1518. [6] Atreya, S.K., et al. (1997) in The Three Galileos: The Man, the Spacecraft, the Telescope, pp. 249–260 (C. Barbieri et al., eds.). [7] Showman A.P., Ingersoll A.P. (1998) Icar, 132, 205–220. [8] Friedson A.J. (2005) Icar, 177, 1–17. [9] de Pater I., et al. (2001) Icar, 149, 66–78. [10] Li C., et al. (2017) GeoRL, 44, 5317–5325. [11] de Pater I., et al. (2019) Icar, 322, 168–191. [12] Fletcher L.N., et al. (2009) Icar, 202, 543–564. [13] National Research Council (2011) Vision and Voyages. [14] Sayanagi K.M., et al. (2020) SSRv, 216, 72. [15] Wong M.H. et al. (2021) BAAS, 53, 486. [16] Zide A., Mendoza-Hill A., Cheney D. (2022) COSPAR Abstracts H0.6-0012-22.

Michael H Wong↗

NASA NTRSDate not supplied

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

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 require 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.

Nathaniel Olson↗

NASA NTRSDate not supplied

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

Nathaniel Olson↗

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 NTRS1984

U.S. planetary exploration program technology implications

As a consequence of the widespread acceptance of the recommendations of the Solar System Exploration Committee, the U.S. Program for exploring the planets has entered a new phase. The objectives to be pursued involve a reduction of costs, while maintaining a high level of scientific return. Plans for the activities to be conducted in this new phase are related to a Core Program and to 'augmentation missions'. One part of the Core Program is concerned with the utilization of the technology, developed for earth-orbiting spacecraft, in missions within the inner solar system to targets ranging from Venus to the inner portion of the asteroid belt. However, modified earth-orbiting buses are not suitable for missions outside the inner solar system. For the second part of the Core Program, which is concerned with the outer solar system and small bodies, a modularized spacecraft based on Viking, Voyager, and Galileo technology will be developed. 'Augmentation missions' will be conducted when possible or desirable.

Diaz, A. V.↗