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High level summary of ground test capabilities available at NASA Ames Research Center that can aid in the development and design of future Outer Planet (Saturn and Uranus) probe missions
A new approach to arc jet testing that replicates the time-varying conditions of atmospheric entry heating was demonstrated. The concept relies on the spatial variation of heat flux and pressure around a cylindrical test article. The spatial variation is transformed to a temporal variation at one location by rotating the test article during exposure to the arc jet stream. The test article rotation mechanism is based on a programmable stepper motor. An entry heat flux profile was mapped to the cylinders heat flux distribution to determine the rotation angle vs. time executed by the mechanism. A series of arc jet tests with instrumented cylindrical TPS test articles was conducted to prove the concept.
The 2013 Decadal Survey for New Frontiers missions identifies several high-value science missions, including Comet Surface Sample Return (CSSR). A CSSR mission will advance the scientific community's fundamental understanding of the origin of the solar system and the contribution of comets to the volatile inventory of the Earth. An entry capsule, or earth entry vehicle (EEV), is be required to protect the scientific payload from the extreme conditions of atmospheric entry, descent, and landing. The Decadal Survey Mission Concept Study along with an APL (Johns Hopkins University Applied Physics Lab) 2007-2008 Comet Surface Sample Mission Study details several of the driving requirements for a CSSR EEV; these include a payload volume and mass and inertial entry velocity of 9 kilometers per second. The mission concept study selected a Multi-Mission Earth Entry Vehicle (MMEEV) design concept derived from the Mars Sample Return (MSR) entry capsule design because of its increased reliability over a parachute-based vehicle. This presentation will explore detailed design of a CSSR-capable Earth Entry Vehicle, including trajectories, aeroheating predictions and associated thermal protection system masses, and onboard instrumentation for entry science.
A review of the current facility capabilities for testing Thermal Protection Systems and quantifying their entry environments at NASA Ames Research Center is presented based on the expected targets of interest to the Planetary Science and Astrobiology communities. While the operational capabilities of these facilities are generally considered sufficient for supporting future missions to targets of interest, expanded ground test capabilities such as larger sample sizes, flight-relevant gas mixtures, dusty environments, and flight-relevant shear/pressure combinations would reduce future entry vehicle design uncertainties and applied margins. These reduced uncertainties may translate into reduced entry vehicle masses, increased robustness, and decreased operational risks during entry phases for science missions. Expanded ground test capabilities would also offer the ability to study material failure modes in environments even more representative of flight than are currently achievable. A list of desired future test capabilities is presented along with suggestions of possible methods of achieving each. The main recommendation of this paper is the undertaking of a detailed study of the benefits and associated costs of each of these expanded capabilities to determine the best future path.
Computational simulations and analysis of flow characterization tests in a high enthalpy arc-jet facility at NASA Ames Research Center are reported. These tests were conducted in the 10-MW TP3 facility 15-inch conical nozzle, and pitot pressure and heat flux probes are used to survey test flow downstream of the nozzle exit. Two 1.59-cm (0.625 in) diameter hemisphere probes were used: one with a stagnation-point pressure port, the other with a Gardon heat flux gage. Calibration data were also obtained using 10.16-cm iso-q and 20.32-cm flat-faced slug calorimeters. Experimental surveys of arc-jet test flow with pitot pressure and heat flux probes were obtained at eight arc-heater conditions, covering wide ranges in arc current (316–1756 A) and mass flow rate (32–500 g/s, without any cold-gas injection at the arc-heater plenum) and providing assessment of the flow uniformity in the facility. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested. These simulations take into account non-uniform total enthalpy and mass flux profiles at the nozzle inlet as well as the expansion waves emanating from the nozzle exit and their effects on the model flowfields. Comparisons of computations with the experimental measurements are presented, showing reasonably good agreement. The probe survey data and accompanying analysis show that the test flow in the TP3 15-inch nozzle is highly non-uniform at most conditions, and the extent of flow non-uniformity depends on arc current and mass flow rate.
Computational simulations and analysis of flow characterization tests in a high enthalpy arc-jet facility at NASA Ames Research Center are reported. These tests were conducted in the 10-MW TP3 facility 15-inch conical nozzle, and pitot pressure and heat flux probes are used to survey test flow downstream of the nozzle exit. Two 1.59-cm (0.625 in) diameter hemisphere probes were used: one with a stagnation-point pressure port, the other with a Gardon heat flux gage. Calibration data were also obtained using 20.32-cm flat-faced slug calorimeters. Experimental surveys of arc-jet test flow with pitot pressure and heat flux probes were obtained at eight arc-heater conditions, covering wide ranges in arc current (316–1756 A) and mass flow rate (32–500 g/s, without any cold-gas injection at the arc-heater plenum) and providing assessment of the flow uniformity in the facility. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested. These simulations take into account non-uniform total enthalpy and mass flux profiles at the nozzle inlet as well as the expansion waves emanating from the nozzle exit and their effects on the model flowfields. Comparisons of computations with the experimental measurements are presented, showing reasonably good agreement. The probe survey data and accompanying analysis show that the test flow in the TP3 15-inch nozzle is highly non-uniform at most conditions, and the extent of flow non-uniformity depends on arc current and mass flow rate.
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This paper reports computational simulations of a high-enthalpy panel test facility at NASA Ames Research Center. The recently developed facility configuration uses a truncated version of an existing semi-elliptical nozzle in the 60-MW Interaction Heating Facility, and it provides testing capability for panel test articles as large as 43.2 cm x 43.2 cm (17 in x 17 in). A water-cooled calibration plate, which is attached to the semi-elliptical nozzle bottom surface and instrumented with twenty Gardon-gage heat flux calorimeters and twelve pressure gages, is used to characterize the convective heating environment over the panel test articles. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, and the flowfields over panel test articles. Both laminar and turbulent simulations are performed, and the computational results are compared with the calibration plate measurements. Comparisons of computed and measured heat fluxes indicate that the boundary layer in the semi-elliptical nozzle is transitional at certain conditions (relatively higher arc-heater pressures or mass flow rates).
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This paper introduces a method for assessing similarity between available shock-layer radiation measurements and the radiative heating to a vehicle of interest. This method will be referred to as the flowfield property binning (FPB) approach. The challenge in developing this approach is that radiometer measurements from a surface normal line of sight, observed radiation measurements of the entire shock-layer from a distance, or measured shock-tube nonequilibrium profiles are notably different geometrically than the radiative flux to a vehicle surface. Therefore, the relative contributions of various regions of the shock-layer to the measurement, and how these relative contributions compare with the radiative heating to a vehicle of interest, are unclear. By tracking the radiation contribution from each flowfield location, and then grouping this contribution based on two local flowfield properties, these geometric differences are removed. This provide a two dimensional group, or bin, distribution that represents the radiation environment in the same format for various types of radiation simulations, such as observed radiation or radiative flux to a vehicle surface. In the limits of optically-thin radiation transport and thermochemical equilibrium flow, the choice of pressure and temperature as the binning flowfield properties is shown to provide a bin distribution that uniquely defines the radiation simulation. This concept is found to be sufficient for establishing similarity between two cases even when the optically-thin radiation transport and thermochemical equilibrium assumptions are not satisfied. A simple metric of comparison between bin distributions from different cases is provided by the histogram intersection algorithm. This algorithm results in a histogram intersection factor (H) between 0 and 1, which represents the fraction of the radiation that is similar between the two cases. Therefore, if H evaluated between bin distributions for two completely different radiation problems is near 1, then they represent essentially the same radiation problem. This means that they depend on the same weighting of various radiation modeling parameters evaluated at the same pressure and temperature. If one of these cases agrees well with a radiation measurement, then the matching bin distributions provide justification for applying this experimental validation to the other case. Even for H values as low as 0.2, the measurement case could be considered relevant if there are no other useful measurements. This approach allows observed radiation measurements to directly inform radiative heating simulations, which allows NASA’s past and future investments in observed radiation measurements to directly inform the radiative heating uncertainty or margins for future vehicle design. This FPB approach is also used to determine shock-tube conditions for informing backshell radiative heating simulations, where the normal shock velocity and Lagrangian time from the shock is used for the binning variables instead of pressure and temperature.
On February 18th, 2021, the Mars 2020 entry vehicle delivered the Perseverance rover to the surface of Mars. The entry vehicle carried a set of instrumentation installed on the heatshield and backshell to measure aerodynamic and aerothermal performance, named the Mars Entry, Descent, and Landing Instrumentation 2. This set of instrumentation included pressure transducers, thermocouples, heatflux sensors, and a radiometer, as well as a dedicated sensor support electronics system. All MEDLI2 hardware operated as expected during cruise and entry. MEDLI2 sensors gathered accurate pressure measurements in hypersonic through supersonic regimes to reconstruct vehicle attitude and atmospheric profiles. MEDLI2 on the heatshield sensors indicated that surface temperatures, caused by turbulent heating beginning 70 seconds after entry, remained at or below 1430 °C, while heatshield bondline temperatures rose less than 45 °C. Backshell surface TPS temperatures peaked at 630 °C, which was caused primarily by radiative heating measured by several separate sensors. The MEDLI2 temperature and pressure measurements enabled further detailed characterization of the Mars 2020 entry performance, and the flight dataset will provide a wealth of information for the EDL community and future mission designers.
On February 18th, 2021, the Mars 2020 entry vehicle delivered the Perseverance rover to the surface of Mars. The entry vehicle carried a set of instrumentation installed on the heatshield and backshell to measure aerodynamic and aerothermal performance, named the Mars Entry, Descent, and Landing Instrumentation 2. This set of instrumentation included pressure transducers, thermocouples, heatflux sensors, and a radiometer, as well as a dedicated sensor support electronics system. All MEDLI2 hardware operated as expected during cruise and entry. MEDLI2 sensors gathered accurate pressure measurements in hypersonic through supersonic regimes to reconstruct vehicle attitude and atmospheric profiles. MEDLI2 on the heatshield sensors indicated that surface temperatures, caused by turbulent heating beginning 70 seconds after entry, remained at or below 1430 °C, while heatshield bondline temperatures rose less than 45 °C. Backshell surface TPS temperatures peaked at 630 °C, which was caused primarily by radiative heating measured by several separate sensors. The MEDLI2 temperature and pressure measurements enabled further detailed characterization of the Mars 2020 entry performance, and the flight dataset will provide a wealth of information for the EDL community and future mission designers.
This paper describes recent development of modeling and simulation technologies for entry systems in support of NASA’s exploration missions. Mission-tailored research and development in modeling of entry systems occurs across the Agency (e.g., within the Orion and Mars 2020 Programs), however the aim of this paper is to discuss the broad, cross-mission research conducted by NASA’s Entry Systems Modeling (ESM) Project, which serves as the Agency’s only concerted effort toward advancing entry systems across a range of technical disciplines. Technology development in ESM is organized and prioritized from a system-level perspective, resulting in four broad technical areas of investment: (1) Predictive material modeling, (2) Shock layer kinetics and radiation, (3) Computational and experimental aerosciences, and (4) Guidance, navigation, and control. Investments in thermal protection material modeling are geared toward high-fidelity, predictive models capable of handling complex structures, with an eye toward optimizing design performance and quantifying thermal protection system reliability. New computational tools have been developed to characterize material properties and behavior at the microstructural level, and experimental techniques (molecular beam scattering, micro-computed tomography, among others) have been developed to measure material kinetics, morphology, and other parameters needed to inform and validate detailed simulations. Advancements have also been made in macrostructural simulation capability to enable 3-D system-scale calculations of material response with complex topological features, including differential recession of tile gaps. Research and development in the area of shock layer kinetics has focused on air and CO2-based atmospheres. Capacity and capability of the NASA Ames Electric Arc Shock Tube (EAST) have been expanded in recent years and analysis of resulting data has led to several improvements in kinetic models, while simultaneously reducing uncertainties associated with radiative heat transfer predictions. First-principles calculations of fundamental kinetic, thermodynamic, and transport data, along with state-specificmodels for non-equilibrium flow regimes, have also yielded new insights and have the potential to vastly improve model fidelity. Aerosciences is a very broad area of interest in entry systems, yet a number of important challenges are being addressed: Coupled fluid-structure simulations of parachute inflation and dynamics; Experimental and computational studies of vehicle dynamics; Multi-phase flow with dust particles to simulate entry environments at Mars during dust storms; Studies of roughness-induced heating augmentation relevant to tiled and woven thermal protection systems; and Advanced numerical methods to optimize computational analyses for desired accuracy versus cost. Guidance and control in the context of entry systems has focused on development of methods for multi-axis control (i.e. pitch and yaw, rather than bank angle alone) of spacecraft during entry and descent. With precision landing requirements driven by Mars human exploration goals, recent efforts have yielded 6-DOF models of multi-axis control with propulsive descent of both inflatable and rigid ellipsled-like architectures. Results for both configurations have demonstrated the ability to land within the 50-meter precision requirement demanded by Mars human exploration missions, while also reducing propellant requirements by enabling more efficient control through entry and descent. Ongoing research in GN&C is developing mechanical specifications for the systems and establishing engineering feasibility.
An arc-jet test campaign is used as a baseline to computationally model the flow and material response of cavities. A parametric study is designed around the baseline to study geometric effects on parameters of interest. The US3D flow solver is used to simulate the arc-jet flow in the Aerodynamic Heating Facility (AHF) at NASA Ames and generate the heating environment over material samples with cavities. The Icarus material response code is then used to simulate the multi-dimensional heating under the above conditions of samples of FiberForm with cavities.
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Recent Hayabusa 2 spectral measurements are compared with state-of-the-art shock-layer radiation simulations resulting from the LAURA/HARA code suite. These simulations include coupled ablation, which accounts for the injection of ablation products into the flowfield, and coupled radiation, which accounts for radiative energy loss in the flowfield. To enable the cou- pled ablation simulations, a best-estimate model is developed for Hayabusa’s carbon-phenolic ablator based on available published information. The comparison between the simulations and measurements focuses on three atomic nitrogen lines, two atomic oxygen lines, one atomic hydrogen line, and the CN Violet band system. Parametric uncertainties are evaluated for these features using a recently developed capability in LAURA/HARA. These uncertainties capture the impact of flowfield and radiation modeling uncertainties on the observed radiation simulations, and include the impact of coupled radiation and ablation product emission. The resulting parametric uncertainties range from 50 to over 100% for the atomic lines, and 80% for CN Violet. Uncertainties in flowfield kinetics and non-Boltzmann modeling provide the dominant contribution to these uncertainties. For the atomic nitrogen and oxygen lines, com- parisons between the nominal simulations and measurements show agreement well within these simulation uncertainty bounds, with the measurements within 20% of the nominal simulation over most of the trajectory, and within 10% at peak emission. This excellent agreement is un- precedented for observed radiation measurements of atomic lines, where previous Stardust and Hayabusa 1 comparisons were significantly worse. The improved agreement for these Hayabusa 2 comparisons is both the result of improved measurement quality and enhanced flowfield and radiation modeling. For the ablation product emission from the 656 nm atomic hydrogen line, the agreement between measurements and simulations is within ±20% for all trajectory points except one outlier. This good comparison is surprising considering this species depends on the ablation rate and is shown to have strong wake contribution, which both contribute to the large ≈±70% parametric uncertainty. For the ablation product emission from CN Violet, the simulations over-predict the measurements by over a factor of two early in the trajectory, with the comparison improving later in the trajectory. This disagreement for CN Violet is consistent with the ≈±80% parametric uncertainty bounds evaluated for the simulations. To utilize the excellent agreement between the atomic line simulations and measurements in the assessment of the radiative heating margin for a future flight vehicle, the flowfield property binning (FPB) approach is applied. Using the Mars Sample Return (MSR) Earth Entry System (EES) as an example, the combination of the excellent Hayabusa comparisons and the FPB analysis justify nearly a 10% reduction in the radiative heating margin from an assumed baseline margin of 30%. This direct quantitative link between observed radiation measurements and the radia- tive heating margin of future flight vehicles demonstrates the value of these observed radiation measurements.