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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Performance of Whipple Shields at Impact Velocities above 9 km/s

Whipple shields were first proposed as a means of protecting spacecraft from the impact of micrometeoroids in 1947 [1] and are currently in use as micrometeoroid and orbital debris shields on modern spacecraft. In the intervening years, the function of the thin bumper used to shatter or melt threatening particles has been augmented and enhanced by the use of various types and configurations of intermediate layers of various materials. All shield designs serve to minimize the threat of a spall failure or perforation of the main wall of the spacecraft as a result of the impact of the fragments. With increasing use of Whipple shields, various ballistic limit equations (BLEs) for guiding the design and estimating the performance of shield systems have been developed. Perhaps the best known and most used are the "new" modified Cour-Palais (Christiansen) equations [2]. These equations address the three phases of impact: (1) ballistic (<3 km/s), where the projectile is moving too slowly to fragment and essentially penetrates as an intact projectile; (2) shatter (3 to 7 km/s), where the projectile fragments at impact and forms an expanding cloud of debris fragments; and (3) melt/vaporization (>7 km/s), where the projectile melts or vaporizes at impact. The performance of Whipple shields and the adequacy of the BLEs have been examined for the first two phases using the results of impact tests obtained from two-stage, light-gas gun test firings. Shield performance and the adequacy of the BLEs has not been evaluated in the melt/vaporization phase until now because of the limitations of launchers used to accelerate projectiles with controlled properties to velocities above 7.5 km/s. A three-stage, light-gas gun, developed at the University of Dayton Research Institute (UDRI) [3], is capable of launching small, aluminum spheres to velocities above 9 km/s. This launcher was used to evaluate the ballistic performance of two Whipple shield systems, various thermal protection system materials, and other spacecraft-related materials to the impact of 1.6-mm- to 2.6-mm-diameter, 2017-T4 aluminum spheres at impact velocities ranging from 8.91 km/s to 9.28 km/s. Test results, details of the shield systems, and nominal ballistic limits for the two Whipple shields are shown in Figures 1 and 2.

Christiansen, Eric L.↗
NASA NTRS2011

Radiation Shielding of Lunar Regolith/Polyethylene Composites and Lunar Regolith/Water Mixtures

Space radiation is a complex mixed field of ionizing radiation that can pose hazardous risks to sophisticated electronics and humans. Mission planning for lunar exploration and long duration habitat construction will face tremendous challenges of shielding against various types of space radiation in an attempt to minimize the detrimental effects it may have on materials, electronics, and humans. In late 2009, the Lunar Crater Observation and Sensing Satellite (LCROSS) discovered that water content in lunar regolith found in certain areas on the moon can be up to 5.6 +/-2.8 weight percent (wt%) [A. Colaprete, et. al., Science, Vol. 330, 463 (2010). ]. In this work, shielding studies were performed utilizing ultra high molecular weight polyethylene (UHMWPE) and aluminum, both being standard space shielding materials, simulated lunar regolith/ polyethylene composites, and simulated lunar regolith mixed with UHMWPE particles and water. Based on the LCROSS findings, radiation shielding experiments were conducted to test for shielding efficiency of regolith/UHMWPE/water mixtures with various percentages of water to compare relative shielding characteristics of these materials. One set of radiation studies were performed using the proton synchrotron at the Loma Linda Medical University where high energy protons similar to those found on the surface of the moon can be generated. A similar experimental protocol was also used at a high energy spalation neutron source at Los Alamos Neutron Science Center (LANSCE). These experiments studied the shielding efficiency against secondary neutrons, another major component of space radiation field. In both the proton and neutron studies, shielding efficiency was determined by utilizing a tissue equivalent proportional counter (TEPC) behind various thicknesses of shielding composite panels or mixture materials. Preliminary results from these studies indicated that adding 2 wt% water to regolith particles could increase shielding of the regolith materials by about 6%. The findings may be utilized to extend the possibilities of potential candidate materials for lunar habitat structures, will potentially impact the design criteria of future human bases on the moon, and provide some guidelines for future space mission planning with respect to radiation exposure and risks posed on astronauts.

Johnson, Quincy F.↗
NASA NTRS2004

Flexible Shields for Protecting Spacecraft Against Debris

A report presents the concept of Flexshield a class of versatile, lightweight, flexible shields for protecting spacecraft against impacts by small meteors and orbiting debris. The Flexshield concept incorporates elements of, but goes beyond, prior spacecraft-shielding concepts, including those of Whipple shields and, more recently, multi-shock shields and multi-shock blankets. A shield of the Flexshield type includes multiple outer layers (called bumpers in the art) made, variously, of advanced ceramic and/or polymeric fibers spaced apart from each other by a lightweight foam. As in prior such shields, the bumpers serve to shock an impinging hypervelocity particle, causing it to disintegrate vaporize, and spread out over a larger area so that it can be stopped by an innermost layer (back sheet). The flexibility of the fabric layers and compressibility of the foam make it possible to compress and fold the shield for transport, then deploy the shield for use. The shield can be attached to a spacecraft by use of snaps, hook-and-pile patches, or other devices. The shield can also contain multilayer insulation material, so that it provides some thermal protection in addition to mechanical protection.

Christiansen, Eric L.↗
DOE OSTI2022

The Simons Observatory: Magnetic Shielding Measurements for the Universal Multiplexing Module

The Simons Observatory (SO) includes four telescopes that will measure the temperature and polarization of the cosmic microwave background using over 60,000 highly sensitive transition-edge bolometers (TES). These multichroic TES bolometers are read out by a microwave RF SQUID multiplexing system with a multiplexing factor of 910. Given that both TESes and SQUIDs are susceptible to magnetic field pickup and that it is hard to predict how they will respond to such fields, it is important to characterize the magnetic response of these systems empirically. This information can then be used to limit spurious signals by informing magnetic shielding designs for the detectors and readout. This paper focuses on measurements of magnetic pickup with different magnetic shielding configurations for the SO universal multiplexing module (UMM), which contains the SQUIDs, associated resonators, and TES bias circuit. The magnetic pickup of a prototype UMM was tested under three shielding configurations: no shielding (copper packaging), aluminum packaging for the UMM, and a tin/lead-plated shield surrounding the entire dilution refrigerator 100 mK cold stage. We also present measurements of the pickup in the UMM when aluminum feedhorns are installed. The measurements show that the aluminum packaging outperforms the copper packaging by a shielding factor of 8-10, and adding the tin/lead-plated 1K shield further increases the relative shielding factor in the aluminum configuration by 1-2 orders of magnitude. Furthermore, the addition of feedhorns provides a factor of 30 improvement when the tin/lead shield is not installed and a factor of 5 improvement when it is.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Flexible 3D printed silicones for gamma and neutron radiation shielding

Here, resin formulations for direct ink write (DIW) additive manufacturing (AM) were developed for facile customization to shield radiation signatures consisting of a range of gamma radiation and neutron energies in a variety of applications. The resin developed in this work has been formulated to accommodate very high loadings of shielding filler materials: up to 40 wt% bismuth (Bi) metal for gamma radiation shielding, and up to 60 wt% boron-10 ( 10 B) metal for neutron shielding. We report the first instance of a printable resin containing 60 wt% 10 B, which remains flexible after curing despite the high solids content. We demonstrate that these resins can not only tolerate formulation modulation for radiation profile-matched shielding, but they can also be printed in a variety of geometries such that mechanical properties of the printed shield are readily tuned to specific applications. In contrast, most existing shielding materials are rigid, bulky, and do not allow for the complex shapes and mechanical flexibility needed in high-usage applications. This work demonstrates the successful development of a tunable resin for additively manufactured, flexible radiation shielding material, containing high loadings of shielding filler, which can be utilized in harsh radiation environments associated with nuclear materials.

61 RADIATION PROTECTION AND DOSIMETRY↗
NASA NTRS1989

Trailer shield assembly for a welding torch

This invention relates generally to trailer shields for gas shielded arc welding torches, and more particularly to a trailer shield assembly provided with a shield gas manifold for providing an even dispersion of shield gas to the interior of the shield assembly, which generally encloses a joint being welded and a welding trailing portion of hot welded metal. The novelty of the invention lies in providing trailer shield with a manifold tube having a plurality of openings from which shield gas is distributed. A gas manifold region ahead of the torch is also provided with shield gas from a tube to protect metal preheated by the torch. Further novelty lies in constructing portions of sides and housing and portions of side walls of the guide of stainless steel screen having a tight mesh.

Dyer, Gerald E.↗
NASA NTRS1990

Intercalated graphite fiber composites as EMI shields in aerospace structures

The requirements for electromagnetic interference (EMI) shielding in aerospace structures are complicated over that of ground structures by their weight limitations. As a result, the best EMI shielding materials must blend low density, high strength, and high elastic modulus with high shielding ability. In addition, fabrication considerations including penetrations and joints play a major role. The EMI shielding properties are calculated for shields formed from pristine and intercalated graphite fiber/epoxy composites and compared to preliminary experimental results and to shields made from aluminum. Calculations indicate that EMI shields could be fabricated from intercalated graphite composites which would have less than 12 percent of the mass of conventional aluminum shields, based on mechanical properties and shielding properties alone.

Gaier, James R.↗
NASA NTRS1991

Shield sizing and response equations

A consolidated list is presented of meteoroid debris shield equations which have been given in the referenced memorandums. In some cases, equations have been updated; thus, this memorandum supersedes reference 1. The equations are presented in two parts: (1) shield sizing equations which are used to produce preliminary estimates of shielding weights; and (2) response equations to describe the impact conditions (projectile size as a function of velocity, density, and impact angle) causing failure of a given shield that are to be used for probability analyses (such as in the modified BUMPER program). Specific equations are given that are applicable for the following types of shields: aluminum Whipple shields; Nextel multishock (MS) shields; and mesh double bumper (MDB) shields. These equations will be updated in the future as warranted by the results of additional HVI tests, analyses, and shield modeling.

Christiansen, Eric L.↗
NASA NTRS1992

Intercalated graphite fiber composites as EMI shields in aerospace structures

The requirements for electromagnetic interference (EMI) shielding in aerospace structures are more complicated than those for ground structures because of their weight limitations. As a result, the best EMI shielding materials must combine low density, high strength, and high elastic modulus with high shielding ability. EMI shielding characteristics were calculated for shields formed from pristine and intercalated graphite fiber/epoxy composites and compare to preliminary experimental results for these materials and to the characteristics of shields made from aluminum. Calculations indicate that effective EMI shields could be fabricated from intercalated graphite composites which would have less than 12 percent of the mass of conventional aluminum shields, based on mechanical properties and shielding characteristics alone.

Gaier, James R.↗
NASA NTRS2008

A Review of Radiolysis Concerns for Water Shielding in Fission Surface Power Applications

This paper presents an overview of radiolysis concerns with regard to water shields for fission surface power. A review of the radiolysis process is presented and key parameters and trends are identified. From this understanding of the radiolytic decomposition of water, shield pressurization and corrosion are identified as the primary concerns. Existing experimental and modeling data addressing concerns are summarized. It was found that radiolysis of pure water in a closed volume results in minimal, if any net decomposition, and therefore reduces the potential for shield pressurization and corrosion. With the space program focus m emphasize more on permanent return to the Moon and eventually manned exploration of Mars, there has been a renewed look at fission power to meet the difficult technical & design challenges associated with this effort. This is due to the ability of fission power to provide a power rich environment that is insensitive to solar intensity and related aspects such as duration of night, dusty environments, and distance from the sun, etc. One critical aspect in the utilization of fission power for these applications of manned exploration is shielding. Although not typically considered for space applications, water shields have been identified as one potential option due to benefits in mass savings and reduced development cost and technical risk (Poston, 2006). However, the water shield option requires demonstration of its ability to meet key technical challenges including such things as adequate natural circulation for thermal management and capability for operational periods up to 8 years. Thermal management concerns have begun to be addressed and are not expected to be a problem (Pearson, 2007). One significant concern remaining is the ability to maintain the shield integrity through its operational lifetime. Shield integrity could be compromised through shield pressurization and corrosion resulting from the radiolytic decomposition of water.

Schoenfeld, Michael P.↗
NASA NTRS2008

Gravity Scaling of a Power Reactor Water Shield

Water based reactor shielding is being considered as an affordable option for use on initial lunar surface power systems. Heat dissipation in the shield from nuclear sources must be rejected by an auxiliary thermal hydraulic cooling system. The mechanism for transferring heat through the shield is natural convection between the core surface and an array of thermosyphon radiator elements. Natural convection in a 100 kWt lunar surface reactor shield design has been previously evaluated at lower power levels (Pearson, 2007). The current baseline assumes that 5.5 kW are dissipated in the water shield, the preponderance on the core surface, but with some volumetric heating in the naturally circulating water as well. This power is rejected by a radiator located above the shield with a surface temperature of 370 K. A similarity analysis on a water-based reactor shield is presented examining the effect of gravity on free convection between a radiation shield inner vessel and a radiation shield outer vessel boundaries. Two approaches established similarity: 1) direct scaling of Rayleigh number equates gravity-surface heat flux products, 2) temperature difference between the wall and thermal boundary layer held constant on Earth and the Moon. Nussult number for natural convection (laminar and turbulent) is assumed of form Nu = CRa(sup n). These combined results estimate similarity conditions under Earth and Lunar gravities. The influence of reduced gravity on the performance of thermosyphon heat pipes is also examined.

Reid, Robert S.↗
NASA NTRS2009

Honeycomb vs. Foam: Evaluating a Potential Upgrade to ISS Module Shielding for Micrometeoroids and Orbital Debris

The presence of a honeycomb core in a multi-wall shielding configuration for protection against micrometeoroid and orbital debris (MMOD) particle impacts at hypervelocity is generally considered to be detrimental as the cell walls act to restrict fragment cloud expansion, creating a more concentrated load on the shield rear wall. However, mission requirements often prevent the inclusion of a dedicated MMOD shield, and as such, structural honeycomb sandwich panels are amongst the most prevalent shield types. Open cell metallic foams are a relatively new material with novel mechanical and thermal properties that have shown promising results in preliminary hypervelocity impact shielding evaluations. In this study, an ISS-representative MMOD shielding configuration has been modified to evaluate the potential performance enhancement gained through the substitution of honeycomb for open cell foam. The baseline shielding configuration consists of a double mesh outer layer, two honeycomb sandwich panels, and an aluminum rear wall. In the modified configuration the two honeycomb cores are replaced by open-cell foam. To compensate for the heavier core material, facesheets have been removed from the second sandwich panel in the modified configuration. A total of 19 tests on the double layer honeycomb and double layer foam configurations are reported. For comparable mechanical and thermal performance, the foam modifications were shown to provide a 15% improvement in critical projectile diameter at low velocities (i.e. 3 km/s) and a 3% increase at high velocities (i.e. 7 km/s) for normal impact. With increasing obliquity, the performance enhancement was predicted to increase, up to a 29% improvement at 60 (low velocity). Ballistic limit equations have been developed for the new configuration, and consider the mass of each individual shield component in order to maintain validity in the event of minor configuration modifications. Previously identified weaknesses of open cell foams for hypervelocity impact shielding such as large projectile diameters, low velocities, and high degrees of impact obliquity have all been investigated, and found to be negligible for the double-layer configuration.

Ryan, Shannon↗
NASA NTRS2013

Weight Assessment for Fuselage Shielding on Aircraft With Open-Rotor Engines and Composite Blade Loss

The Federal Aviation Administration (FAA) has been engaged in discussions with airframe and engine manufacturers concerning regulations that would apply to new technology fuel efficient "openrotor" engines. Existing regulations for the engines and airframe did not envision features of these engines that include eliminating the fan blade containment systems and including two rows of counter-rotating blades. Damage to the airframe from a failed blade could potentially be catastrophic. Therefore the feasibility of using aircraft fuselage shielding was investigated. In order to establish the feasibility of this shielding, a study was conducted to provide an estimate for the fuselage shielding weight required to provide protection from an open-rotor blade loss. This estimate was generated using a two-step procedure. First, a trajectory analysis was performed to determine the blade orientation and velocity at the point of impact with the fuselage. The trajectory analysis also showed that a blade dispersion angle of 3deg bounded the probable dispersion pattern and so was used for the weight estimate. Next, a finite element impact analysis was performed to determine the required shielding thickness to prevent fuselage penetration. The impact analysis was conducted using an FAA-provided composite blade geometry. The fuselage geometry was based on a medium-sized passenger composite airframe. In the analysis, both the blade and fuselage were assumed to be constructed from a T700S/PR520 triaxially-braided composite architecture. Sufficient test data on T700S/PR520 is available to enable reliable analysis, and also demonstrate its good impact resistance properties. This system was also used in modeling the surrogate blade. The estimated additional weight required for fuselage shielding for a wing- mounted counterrotating open-rotor blade is 236 lb per aircraft. This estimate is based on the shielding material serving the dual use of shielding and fuselage structure. If the shielding material is not used for dual purpose, and is only used for shielding, then the additional weight per aircraft is estimated to be 428 lb. This weight estimate is based upon a number of assumptions that would need to be revised when applying this concept to an actual airplane design. For example, the weight savings that will result when there is no fan blade containment system, manufacturing limitations which may increase the weight where variable thicknesses was assumed, engine placement on the wing versus aft fuselage, etc.

aircraft safety↗
NASA NTRS2016

Meeting the Grand Challenge of Protecting Astronauts Health: Electrostatic Active Space Radiation Shielding for Deep Space Missions

This report describes the research completed during 2011 for the NASA Innovative Advanced Concepts (NIAC) project. The research is motivated by the desire to safely send humans in deep space missions and to keep radiation exposures within permitted limits. To this end current material shielding, developed for low earth orbit missions, is not a viable option due to payload and cost penalties. The active radiation shielding is the path forward for such missions. To achieve active space radiation shielding innovative large lightweight gossamer space structures are used. The goal is to deflect enough positive ions without attracting negatively charged plasma and to investigate if a charged Gossamer structure can perform charge deflections without significant structural instabilities occurring. In this study different innovative configurations are explored to design an optimum active shielding. In addition, to establish technological feasibility experiments are performed with up to 10kV of membrane charging, and an electron flux source with up to 5keV of energy and 5mA of current. While these charge flux energy levels are much less than those encountered in space, the fundamental coupled interaction of charged Gossamer structures with the ambient charge flux can be experimentally investigated. Of interest are, will the EIMS remain inflated during the charge deflections, and are there visible charge flux interactions. Aluminum coated Mylar membrane prototype structures are created to test their inflation capability using electrostatic charging. To simulate the charge flux, a 5keV electron emitter is utilized. The remaining charge flux at the end of the test chamber is measured with a Faraday cup mounted on a movable boom. A range of experiments with this electron emitter and detector were performed within a 30x60cm vacuum chamber with vacuum environment capability of 10-7 Torr. Experiments are performed with the charge flux aimed at the electrostatically inflated membrane structure (EIMS) in both charged and uncharged configurations. The amount of charge shielding behind and around the EIMS was studied for different combinations of membrane structure voltages and electron energies. Both passive and active shielding were observed, with active shielding capable of deflecting nearly all incoming electrons. The pattern of charge distribution around the structure was studied as well as the stability of the structures in the charge flow. The charge deflection experiments illustrate that the EIMS remain inflated during charge deflection, but will experience small amplitude oscillations. Investigations were performed to determine a potential cause of the vibrations. It is postulated these vibrations are due to the charge flux causing local membrane charge distribution changes. As the membrane structure inflation pressure is changed, the shape responds, and causes the observed sustained vibration. Having identified this phenomenon is important when considering electrostatically inflated membrane structures (EIMS) in a space environment. Additionally, this project included a study of membrane material impacts, specifically the impact of membrane thickness. Extremely thin materials presented new challenges with vacuum preparation techniques and rapid charging. The thinner and lighter membrane materials were successfully inflated using electrostatic forces in a vacuum chamber. However, care must be taken when varying the potentials of such lighter structures as the currents can cause local heating and melting of the very thin membranes. Lastly, a preliminary analysis is performed to study rough order of magnitude power requirements for using EIMS for radiation shielding. The EIMS power requirement becomes increasingly more challenging as the spacecraft voltage is increased. As a result, the emphasis is on the deflection of charges away from the spacecraft rather than totally stopping them. This significantly alleviates the initial power requirements. With modest technological development(s) active shielding is emerging to be a viable option.

Radiation↗
NASA NTRS2012

Radiation Shielding Materials Containing Hydrogen, Boron, and Nitrogen: Systematic Computational and Experimental Study

The key objectives of this study are to investigate, both computationally and experimentally, which forms, compositions, and layerings of hydrogen, boron, and nitrogen containing materials will offer the greatest shielding in the most structurally robust combination against galactic cosmic radiation (GCR), secondary neutrons, and solar energetic particles (SEP). The objectives and expected significance of this research are to develop a space radiation shielding materials system that has high efficacy for shielding radiation and that also has high strength for load bearing primary structures. Such a materials system does not yet exist. The boron nitride nanotube (BNNT) can theoretically be processed into structural BNNT and used for load bearing structures. Furthermore, the BNNT can be incorporated into high hydrogen polymers and the combination used as matrix reinforcement for structural composites. BNNT's molecular structure is attractive for hydrogen storage and hydrogenation. There are two methods or techniques for introducing hydrogen into BNNT: (1) hydrogen storage in BNNT, and (2) hydrogenation of BNNT (hydrogenated BNNT). In the hydrogen storage method, nanotubes are favored to store hydrogen over particles and sheets because they have much larger surface areas and higher hydrogen binding energy. The carbon nanotube (CNT) and BNNT have been studied as potentially outstanding hydrogen storage materials since 1997. Our study of hydrogen storage in BNNT - as a function of temperature, pressure, and hydrogen gas concentration - will be performed with a hydrogen storage chamber equipped with a hydrogen generator. The second method of introducing hydrogen into BNNT is hydrogenation of BNNT, where hydrogen is covalently bonded onto boron, nitrogen, or both. Hydrogenation of BN and BNNT has been studied theoretically. Hyper-hydrogenated BNNT has been theoretically predicted with hydrogen coverage up to 100% of the individual atoms. This is a higher hydrogen content than possible with hydrogen storage; however, a systematic experimental hydrogenation study has not been reported. A combination of the two approaches may be explored to provide yet higher hydrogen content. The hydrogen containing BNNT produced in our study will be characterized for hydrogen content and thermal stability in simulated space service environments. These new materials systems will be tested for their radiation shielding effectiveness against high energy protons and high energy heavy ions at the HIMAC facility in Japan, or a comparable facility. These high energy particles simulate exposure to SEP and GCR environments. They will also be tested in the LaRC Neutron Exposure Laboratory for their neutron shielding effectiveness, an attribute that determines their capability to shield against the secondary neutrons found inside structures and on lunar and planetary surfaces. The potential significance is to produce a radiation protection enabling technology for future exploration missions. Crew on deep space human exploration missions greater than approximately 90 days cannot remain below current crew Permissible Exposure Limits without shielding and/or biological countermeasures. The intent of this research is to bring the Agency closer to extending space missions beyond the 90-day limit, with 1 year as a long-term goal. We are advocating a systems solution with a structural materials component. Our intent is to develop the best materials system for that materials component. In this Phase I study, we have shown, computationally, that hydrogen containing BNNT is effective for shielding against GCR, SEP, and neutrons over a wide range of energies. This is why we are focusing on hydrogen containing BNNT as an innovative advanced concept. In our future work, we plan to demonstrate, experimentally, that hydrogen, boron, and nitrogen based materials can provide mechanically strong, thermally stable, structural materials with effective radiation shielding against GCR, SEP, and neutrons.

Radiation↗
NASA NTRS2017

Early Results from the Advanced Radiation Protection Thick GCR Shielding Project

The Advanced Radiation Protection Thick Galactic Cosmic Ray (GCR) Shielding Project leverages experimental and modeling approaches to validate a predicted minimum in the radiation exposure versus shielding depth curve. Preliminary results of space radiation models indicate that a minimum in the dose equivalent versus aluminum shielding thickness may exist in the 20-30 g/cm2 region. For greater shield thickness, dose equivalent increases due to secondary neutron and light particle production. This result goes against the long held belief in the space radiation shielding community that increasing shielding thickness will decrease risk to crew health. A comprehensive modeling effort was undertaken to verify the preliminary modeling results using multiple Monte Carlo and deterministic space radiation transport codes. These results verified the preliminary findings of a minimum and helped drive the design of the experimental component of the project. In first-of-their-kind experiments performed at the NASA Space Radiation Laboratory, neutrons and light ions were measured between large thicknesses of aluminum shielding. Both an upstream and a downstream shield were incorporated into the experiment to represent the radiation environment inside a spacecraft. These measurements are used to validate the Monte Carlo codes and derive uncertainty distributions for exposure estimates behind thick shielding similar to that provided by spacecraft on a Mars mission. Preliminary results for all aspects of the project will be presented.

Norman, Ryan B.↗
NASA NTRS2019

Orion Heat Shield Manufacturing Producibility Improvements for the EM-1 Flight Test Program

This paper describes how the Orion program is incorporating improvements in the heat shield design and manufacturing processes reducing programmatic risk and ensuring crew safety in support of NASA’s Exploration Missions. The Orion program successfully completed the EFT-1 flight test in 2014 and is currently developing the EM-1 spacecraft to meet the test objectives of an orbital mission to the moon and return to earth in 2019. Lessons learned from the EFT-1 manufacturing and flight test experience are being incorporated into a wide variety of vehicle systems and manufacturing processes to reduce risk to the Orion missions and flight crew. A critical contributor to crew safety is the heat shield that protects the crew capsule during re-entry through the earth’s atmosphere for return from deep space. The first flight test vehicle, EFT-1, was manufactured and tested in the Neil Armstrong Operations and Checkout (O&C) facility at KSC to demonstrate early risk reduction including the functionality of the Thermal Protection Systems (TPS) for capsule safe return to earth. The approach for the EFT-1 heat shield utilized a low risk approach using Apollo heritage design and manufacturing processes using an Avcoat TPS ablator with a honeycomb substrate to provide a one piece heat shield to meet the mission re-entry heating environments. The manufacturing processes used honeycomb cell injection guns which were redeveloped from the Apollo Lunar Program processes to build the EFT-1 heat shield. The completed heat shield was transported across the country by aircraft to the O&C at KSC for installation onto the capsule. The EFT-1 heat shield successfully performed its mission and experienced ~80% of the re-entry velocity (50% heating rate) for a lunar return for an Exploration Mission. The second flight test vehicle is the EM-1 mission which will have additional flight systems installed to fly to the moon and return. Heat shield design and producibility improvements have been incorporated in the EM-1 vehicle to meet deep space mission and programmatic requirements. The design continues to use the Avcoat material, but in a “block” configuration to enable improvements in the application processes as well as additional improvements in the carrier structure design and manufacturing operations. Incorporating flight test results and producibility improvements from EFT-1 for the heat shield system design and processes have improved the thermal protection capability, improved the producibility, and cost for EM-1 flight test.

Producibility↗
DOE OSTI2025

Lightweight, Flexible Electromagnetic Shielding Composite Films Reinforced with Recycled Carbon Fibers and Carbon Nanofillers

Lightweight, flexible polymer composites are widely adopted in modern electronic devices and systems for high-efficiency electromagnetic interference (EMI) shielding. Reinforcing polymer composites with conductive fillers offers a promising alternative to conventional metal-based shielding material thanks to their low density, tunable properties, and flexibility. Herein, lightweight, flexible ultra-high molecular weight polyethylene composite films reinforced with recycled carbon fibers (rCFs) and carbon-based nanofillers, including graphene nanoplatelets (GNPs) and carbon nanotubes, are reported for EMI shielding applications. The incorporation of these nanofillers significantly reduces the required content of rCFs and improves processability while maintaining comparable shielding effectiveness. The addition of these nanofillers with rCFs enhances the EMI shielding effectiveness by up to 15 dB. Incorporating 1 wt% GNPs can replace 5 wt% rCFs and achieve comparable EMI shielding performance, while 5 wt% of either nanofillers can substitute for 10 wt% rCFs. Numerical modeling of electromagnetic wave transmission reveals that increasing nanofiller concentrations enhances both reflection and absorption losses, with absorption consistently dominating across all levels. Furthermore, this study not only provides insight into the synergistic contributions of rCFs and carbon nanofillers to shielding effectiveness but also paves the way for the design of sustainable, lightweight EMI shielding composite films for applications in electric vehicles, medical equipment, and portable electronics.

carbon nanofiller↗