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Earth Entry Vehicle Design for Sample Return Missions Using M-SAPE

Most mission concepts that return sample material to Earth share one common element: an Earth entry vehicle (EEV). The primary focus of this paper is the examination of EEV design space for relevant sample return missions. Mission requirements for EEV concepts can be divided into three major groups: entry conditions (e.g., velocity and flight path angle), payload (e.g., mass, volume, and g-load limit), and vehicle characteristics (e.g., thermal protection system, structural topology, and landing concepts). The impacts of these requirements on the EEV design have been studied with an integrated system analysis tool, and the results will be discussed in details. In addition, through sensitivities analyses, critical design drivers that have been identified will be reviewed.

Samareh, Jamshid↗

A Comprehensive Structural Dynamic Analysis Approach for Multi Mission Earth Entry Vehicle (MMEEV) Development

The anticipated NASA Mars Sample Return Mission (MSR) requires a simple and reliable method in which to return collected Martian samples back to earth for scientific analysis. The Multi-Mission Earth Entry Vehicle (MMEEV) is NASA's proposed solution to this MSR requirement. Key aspects of the MMEEV are its reliable and passive operation, energy absorbing foam-composite structure, and modular impact sphere (IS) design. To aid in the development of an EEV design that can be modified for various missions requirements, two fully parametric finite element models were developed. The first model was developed in an explicit finite element code and was designed to evaluate the impact response of the vehicle and payload during the final stage of the vehicle's return to earth. The second model was developed in an explicit code and was designed to evaluate the static and dynamic structural response of the vehicle during launch and reentry. In contrast to most other FE models, built through a Graphical User Interface (GUI) pre-processor, the current model was developed using a coding technique that allows the analyst to quickly change nearly all aspects of the model including: geometric dimensions, material properties, load and boundary conditions, mesh properties, and analysis controls. Using the developed design tool, a full range of proposed designs can quickly be analyzed numerically and thus the design trade space for the EEV can be fully understood. An engineer can then quickly reach the best design for a specific mission and also adapt and optimize the general design for different missions.

Perino, Scott↗

Mars Exploration: Mission and System Analysis of the Split Sprint Mission

The information presented in this report provides detailed mission and system analysis of the Split Sprint Mission to Mars. These data were generated from September 1987 through July 1988 and involved numerous individuals within Program Development. This mission derives its name from the fact that the total mission payload is split between two vehicles, a cargo vehicle, and a piloted vehicle. The cargo vehicle carries the Mars lander and propellant for the piloted vehicle return to Earth. Then approximately 1 1/2 years later, the piloted vehicle carries the crew on a higher energy "sprint” trajectory to Mars. The advantages of the Split Sprint Mission is that the payload for the piloted vehicle is minimized and the crew would be in space for only 14 months. Mission and system data are presented for a Sprint Mission in the year 2004. Many important aspects of the mission were studied in detail. These include orbital lighting and lifetime analysis, Mars parking orbit selection, Earth departure window analysis, lander descent and ascent performance, vehicle aerobraking requirements, mission orbital maneuvers, and many other analyses listed in the Table of Contents. Emphasis was placed on vehicle performance analysis which ranged from recovery of the Earth departure stages to aerocapture of the Earth Return Capsule. There is also a section describing the computer programs that were used for this study. These programs provide many useful tools for future studies of manned planetary missions. This introductory section will give an overall view of the Split Sprint Mission and describe the orbital operations and vehicles that were studied.

Mars Architecture Team↗

Earth Entry Vehicle for Mars Sample Return

The driving requirement for design of a Mars Sample return mission is assuring containment of the returned samples. The impact of this requirement on developmental costs, mass allocation, and design approach of the Earth Entry Vehicle is significant. A simple Earth entry vehicle is described which can meet these requirements and safely transport the Mars Sample Return mission's sample through the Earth's atmosphere to a recoverable location on the surface. Detailed analysis and test are combined with probabilistic risk assessment to design this entirely passive concept that circumvents the potential failure modes of a parachute terminal descent system. The design also possesses features that mitigate other risks during the entry, descent, landing and recovery phases. The results of a full-scale drop test are summarized.

Mitcheltree, R. A.↗

Trends in high-speed atmospheric flight

Some of the current problems and future trends for three types of flight within the Earth's atmosphere are considered. The three areas examined are atmosphere entry at very high speeds, atmosphere exit of launch vehicles, and sustained cruise within the atmosphere. The high-speed entry problems described are those encountered by vehicles returning to Earth after a manned mission to Mars. Such vehicles will experience atmosphere entry speeds up to 50,000 and perhaps as high as 70,000 feet per second. For these vehicles to execute a successful entry, accurate guidance at Earth approach must be provided and very precise control during the flight within the atmosphere will be a necessity. At the high entry speeds radiative heating-is greater than convective and thus it tends to exert a dominant influence on entry-vehicle configuration. The study and development of relatively slender vehicles is indicated in order to minimize the large radiative heating loads and associated heat-shield weights. Manned interplanetary missions in the future may also involve a need for very large launch vehicles. These large vehicles will have aerodynamic problems which differ somewhat from current problems. For example, drag losses decrease with increasing size and large vehicles may thus be of lower fineness ratio than present-day vehicles. With lower fineness ratio some of the difficult current problems produced by ground-wind loads and by buffet of hammerhead payload mountings will be avoided. In the case of high-speed cruise within the Earth's atmosphere, the use of hydrogen-fueled, airbreathing engines may permit attractive payload capabilities for long-range high-speed transports. For such vehicles aerodynamic problems arise because of the numerous constraints placed upon their flight paths as well as from the large volumes required for the hydrogen fuel. From payload considerations alone, attractive cruise speeds for such vehicles currently appear to be about twice that of the conventionally fueled supersonic transports now being intensively studied.

Atmospheric entry↗

Notes on Earth Atmospheric Entry for Mars Sample Return Missions

The entry of sample return vehicles (SRVs) into the Earth's atmosphere is the subject of this document. The Earth entry environment for vehicles, or capsules, returning from the planet Mars is discussed along with the subjects of dynamics, aerodynamics, and heat transfer. The material presented is intended for engineers and scientists who do not have strong backgrounds in aerodynamics, aerothermodynamics and flight mechanics. The document is not intended to be comprehensive and some important topics are omitted. The topics considered in this document include basic principles of physics (fluid mechanics, dynamics and heat transfer), chemistry and engineering mechanics. These subjects include: a) fluid mechanics (aerodynamics, aerothermodynamics, compressible fluids, shock waves, boundary layers, and flow regimes from subsonic to hypervelocity; b) the Earth s atmosphere and gravity; c) thermal protection system design considerations; d) heat and mass transfer (convection, radiation, and ablation); e) flight mechanics (basic rigid body dynamics and stability); and f) flight- and ground-test requirements; and g) trajectory and flow simulation methods.

Rivell, Thomas↗

A preliminary TPS design for MRSR - Aerobraking at Mars and at earth

An investigation was made to determine the feasibility of using an aerobrake system for an unmanned mission to Mars and for a return vehicle to earth. A preliminary thermal protection system (TPS) is examined for two small nose radius, straight biconic vehicles aerocapturing at Mars. The TPS for these vehicles, entering at 6 km/s and 8 km/s, are shown to have an advantage over a propulsive burn velocity reduction for orbit insertion. The TPS for each vehicle consisted of an ablator in the region of high heating, and reusable insulation over the rest of the structure. It was determined that a reusable TPS could be used over 98 percent of the aeroshell structure. Also presented is the preliminary TPS design for an Apollo-shaped vehicle aerocapturing at earth. As with the biconics, this vehicle had an ablator in the region of high heating, and reusable insulation on the aft conic section. In contrast to the vehicles aerocapturing at Mars, the ablator is used on 63 percent of the vehicle's aeroshell structure.

Williams, S. D.↗

Detailed Design of an Earth Entry Vehicle for Comet Surface Sample Return

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.

Trajectory Analysis↗

Interpretation of Vehicle Tumbling Predictions from 6-DOF Entry and Descent Simulation

Blunt body entry vehicles are subject to dynamic instability during terminal descent. This often manifests as limit cycle oscillations in total angle of attack, but can diverge into tumbling behavior under certain conditions. For the Mars Sample Return Earth Entry Vehicle (MSR EEV), there is a constraint on the orientation of the sample tubes so backward impact is impermissible. Past missions have chosen to deploy parachutes to preclude tumbling, but active events after release of MSR EEV have been ground-ruled out with the intent to maximize system reliability. Prevention of tumbling during subsonic descent is a design driver for MSR EEV. During preliminary design of the MSR EEV, six degree-of-freedom numerical simulations indicated an unacceptably high probability of tumbling for a 60degree sphere-cone forebody geometry, which necessitated a design change. Decreasing the forebody angle was expected to improve dynamic stability, but would also adversely impact mass, aeroheating, and manufacturing risk. Hence there was strong motivation to understand the physical drivers for the onset of tumbling, and to determine: (a) whether the causes of tumbling are representative of physically realizable vehicle entry configurations and (b) what changes can be made to existing design and analysis practices to ensure a stable vehicle.

Entry Vehicle↗

Planetary protection issues for sample return missions

Planetary protection (PP) issues for both a comet nucleus sample return (CNSR) mission and a Mars rover sample return (MRSR) mission are discussed, with special attention given to the PP requirements for such missions, the exobiology science objectives for the CNSR and MRSR missions, and a qualitative PP risk assessment for both mission types. A set of contamination control procedures for both missions is presented, which identify procedures for each of the mission phases (i.e., the prelaunch, launch, sample handling, transit vehicle, and earth return). Recommendations for further research and technology development are discussed.

Devincenzi, D. L.↗

Finite-Rate Ablation Boundary Conditions for Carbon-Phenolic Heat-Shield

A formulation of finite-rate ablation surface boundary conditions, including oxidation, nitridation, and sublimation of carbonaceous material with pyrolysis gas injection, has been developed based on surface species mass conservation. These surface boundary conditions are discretized and integrated with a Navier-Stokes solver. This numerical procedure can predict aerothermal heating, chemical species concentration, and carbonaceous material ablation rate over the heatshield surface of re-entry space vehicles. In this study, the gas-gas and gas-surface interactions are established for air flow over a carbon-phenolic heatshield. Two finite-rate gas-surface interaction models are considered in the present study. The first model is based on the work of Park, and the second model includes the kinetics suggested by Zhluktov and Abe. Nineteen gas phase chemical reactions and four gas-surface interactions are considered in the present model. There is a total of fourteen gas phase chemical species, including five species for air and nine species for ablation products. Three test cases are studied in this paper. The first case is a graphite test model in the arc-jet stream; the second is a light weight Phenolic Impregnated Carbon Ablator at the Stardust re-entry peak heating conditions, and the third is a fully dense carbon-phenolic heatshield at the peak heating point of a proposed Mars Sample Return Earth Entry Vehicle. Predictions based on both finite-rate gas- surface interaction models are compared with those obtained using B' tables, which were created based on the chemical equilibrium assumption. Stagnation point convective heat fluxes predicted using Park's finite-rate model are far below those obtained from chemical equilibrium B' tables and Zhluktov's model. Recession predictions from Zhluktov's model are generally lower than those obtained from Park's model and chemical equilibrium B' tables. The effect of species mass diffusion on predicted ablation rate is also examined.

Chen, Y.-K.↗

Sustaining Phenolic Impregnated Carbon Ablator (PICA) for Future NASA Missions Including Discovery and New Frontiers

Phenolic Impregnated Carbon Ablator (PICA) was invented in the mid 1990's and due to its relatively low density and efficient performance has been the heat shield TPS of choice for a range of missions includ-ing, Stardust, OSIRIS-Rex, Mars Science Laboratry (MSL) and Mars 2020. PICA has also been the TPS solution on numerous Discovery and New Frontiers proposals, as both the heat shield and back shell TPS and is under consideration as both for the Mars Sample Return Earth Entry Vehicle (EEV) and the heat shield on the Sample Retrieval Lander (SRL). Recently NASA's Science Mission Directorate (SMD) has funded an activity to develop a more sus-tainable version of PICA and to expand the demon-strated capabilities of PICA both in manufacturing and aerothermal performance.

Thermal Protection Material↗

Application of Risk Informed Decision Making to Highly Reliable Three Dimensionally Woven Thermal Protection System for Mars Sample Return

The NASA Risk Informed Decision Making process is used to assess a trade space of three dimensionally woven thermal protection systems for application to the Mars Sample Return Earth Entry Vehicle. Candidate architectures are assessed based on mission assurance, technical development, cost, and schedule risk. Assessment methodology differed between the architectures, utilizing a four-point quantitative scale for mission assurance and technical development and highly tailored PERT techniques for cost and schedule. Risk results are presented, in addition to a review of RIDM effectiveness for this application.

Needels, J.↗

Application of Risk Informed Decision Making to a Highly Reliable Three-Dimensionally Woven Thermal Protection System for Mars Sample Return

The NASA Risk Informed Decision Making process is used to assess a trade space of three dimensionally woven thermal protection systems for application to the Mars Sample Return Earth Entry Vehicle. Candidate architectures are assessed based on mission assurance, technical development, cost, and schedule risk. Assessment methodology differed between the architectures, utilizing a four-point quantitative scale for mission assurance and technical development and highly tailored PERT techniques for cost and schedule. Risk results are presented, in addition to a review of RIDM effectiveness for this application.

Needels, J.↗

Boundary-Layer Flow Simulations Over Ablating Woven Thermal Protection System Material

Spallation is the mechanical removal of small chunks of material gets removed typically due to high shear conditions of the flow field. This reduces the ability of the thermal protection system (TPS) material to protect the spacecraft as well as cause turbulence in the flow causing higher heating rates. In this work, we focus on the material removal through ablation and high shear flow within the boundary layer region of woven TPS material. Woven TPS (WTPS) material is the latest class of material developed by NASA, to be used within the next generation of space flights. They are complex interlocked weaves designed to create a rigid structure that is highly resistant to heat and can be easily designed and tailored for a wide variety of entry environments. Due to material removal resulting from chemical degradation, the structural integrity of TPS material is affected. Spallation occurs when this structurally compromised material is exposed to the high shear flow conditions within the boundary layer. In order to understand the spallation mechanism within WTPS material, we first perform the material removal simulations which occur primarily through oxidation to obtain the microstructure at various stages of degradation. These simulations are performed using the Porous Microstructure Analysis (PuMA) software developed at NASA Ames. The micro-structure geometry used within these simulations were generated artificially to be similar to the 3D weave architecture of MSR-EEV (Mars Sample Return - Earth Entry Vehicle). The various eroded TPS micro-structures are then subjected to the boundary layer flow conditions to obtain critical surface quantities which contribute to the structural failure mechanism such as heat flux, pressure, and shear stress. The direct simulation Monte Carlo (DSMC) methodology is used to perform these simulations in order to accurately capture the strong gradients within the high-temperature boundary layer flow over the intricate geometry of WTPS material. The boundary layer profile is directly taken from the Computational Fluid Dynamics (CFD) simulation and provided as boundary conditions to the DSMC inlet and outlet. Further, the variation of these properties as the microstructure undergoes changes due to oxidation is also investigated. Finally, these quantities are used as input in PuMA to understand the material expansion/compression and strain within the woven TPS geometry and help in developing a comprehensive spallation and structure failure model.

microstructure↗

Boundary-Layer Flow Simulations Over Ablating Woven Thermal Protection System Material

Spallation is the mechanical removal of small chunks of material gets removed typically due to high shear conditions of the flow field. This reduces the ability of the thermal protection system (TPS) material to protect the spacecraft as well as cause turbulence in the flow causing higher heating rates. In this work, we focus on the material removal through ablation and high shear flow within the boundary layer region of woven TPS material. Woven TPS (WTPS) material is the latest class of material developed by NASA, to be used within the next generation of space flights. They are complex interlocked weaves designed to create a rigid structure that is highly resistant to heat and can be easily designed and tailored for a wide variety of entry environments. Due to material removal resulting from chemical degradation, the structural integrity of TPS material is affected. Spallation occurs when this structurally compromised material is exposed to the high shear flow conditions within the boundary layer. In order to understand the spallation mechanism within WTPS material, we first perform the material removal simulations which occur primarily through oxidation to obtain the microstructure at various stages of degradation. These simulations are performed using the Porous Microstructure Analysis (PuMA) software developed at NASA Ames. The micro-structure geometry used within these simulations were generated artificially to be similar to the 3D weave architecture of MSR-EEV (Mars Sample Return - Earth Entry Vehicle). The various eroded TPS micro-structures are then subjected to the boundary layer flow conditions to obtain critical surface quantities which contribute to the structural failure mechanism such as heat flux, pressure, and shear stress. The direct simulation Monte Carlo (DSMC) methodology is used to perform these simulations in order to accurately capture the strong gradients within the high-temperature boundary layer flow over the intricate geometry of WTPS material. The boundary layer profile is directly taken from the Computational Fluid Dynamics (CFD) simulation and provided as boundary conditions to the DSMC inlet and outlet. Further, the variation of these properties as the microstructure undergoes changes due to oxidation is also investigated. Finally, these quantities are used as input in PuMA to understand the material expansion/compression and strain within the woven TPS geometry and help in developing a comprehensive spallation and structure failure model.

microstructure↗

Dynamic Stability Test Technique for Blunt Bodies in a Magnetic Suspension and Balance System

Techniques for the measurement of subsonic dynamic stability derivatives of blunt-body re-entry capsules are being developed using a Magnetic Suspension and Balance System at NASA Langley Research Center. The measured aerodynamics of a 45-degree sphere-cone similar to configurations being considered for Mars Sample Return Earth Entry Vehicle are reported. A novel test method has been developed where forced oscillatory translation of a test article is used to excite yaw attitude oscillations. The forced motion is then halted to observe free-to-oscillate behavior of the test article. Parameter identification methods are used to extract drag as well as static and dynamic yawing moment stability characteristics from the measured forces and observed attitude histories. This combination of forced excitation followed by free-to-oscillate dynamics is a repeatable method to produce test article attitude histories that can be used to measure aerodynamic characteristics.

Entry Systems Modeling↗

Dynamic Stability Test Technique for Blunt Bodies in a Magnetic Suspension and Balance System

Techniques for the measurement of subsonic dynamic stability derivatives of blunt-body re-entry capsules are being developed using a Magnetic Suspension and Balance System at NASA Langley Research Center. The measured aerodynamics of a 45-degree sphere-cone similar to configurations being considered for Mars Sample Return Earth Entry Vehicle are reported. A novel test method has been developed where forced oscillatory translation of a test article is used to excite yaw attitude oscillations. The forced motion is then halted to observe free-to-oscillate behavior of the test article. Parameter identification methods are used to extract drag as well as static and dynamic yawing moment stability characteristics from the measured forces and observed attitude histories. This combination of forced excitation followed by free-to-oscillate dynamics is a repeatable method to produce test article attitude histories that can be used to measure aerodynamic characteristics.

Entry Systems Modeling↗