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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Smooth Particle Hydrodynamic Code Predictions for Meteoroid Damage to Thermal Protection Systems Shielded By Composite Structures

Interplanetary spacecraft are exposed to meteoroid fluxes with characteristics far exceeding the physical simulation capabilities of test facilities for predicting the likelihood that a meteoroid will penetrate a spacecraft’s critical systems. Accurate risk predictions are crucial to ensuring that important interplanetary missions, such as sample returns, can survive years of exposure to the meteoroid environment and safely reenter the Earth’s atmosphere with their scientific cargo. In this paper, we summarize a series of meteoroid impact damage computational simulations into two types of spacecraft composite protective structures using the Smooth Particle Hydrodynamics Code. We consider the effects of both meteoric materials and non-meteoric materials on a shielded forebody thermal protection system (TPS) for an extreme entry environment and on an unshielded aftbody TPS that is similar to the material covering the space shuttle’s external tank.

Brooke Corbett↗
NASA NTRS1978

Recent Advances in Structures for Hypersonic Flight, part 2

The papers at this symposium were presented by 24 speakers representing airframe, missile, and engine manufacturers, the U.S. Air Force, and two NASA Research Centers. The papers cover a variety of topics including engine structures, cooled airframe structures, hot structures, thermal protection systems, cryogenic tankage structures, cryogenic insulations, and analysis methods for thermal/structures.

Source record↗
NASA NTRSDate not supplied

Measuring the Wear and Abrasive Resistance of Air Plasma Sprayed Aluminum Oxide for Lunar Exploration

Lunar regolith, especially finer dust particles traveling at high velocities, can cause significant wear and abrasive damage to structural components that ensure a prolongated presence on the surface of the Moon. With the absence of an atmosphere and lower gravity than on Earth, regolith particles maintain high velocities at large distances from where they were generated, for example next to lunar landers. Wear-resistant ceramic and ceramic composite materials can improve the durability of spacecraft components during long missions on the Moon’s surface. Aluminum oxide coatings are lightweight, have multifunctional properties, and have high strength including high hardness and wear resistance. These properties can help improve the durability of structures used in space exploration. Air plasma sprayed (APS) aluminum oxide coatings have demonstrated the potential to protect critical structures. This study investigated the abrasive wear resistance of APS aluminum oxide coatings via Taber abrasion experiments. Taber abrasion offers the advantage of quantifying the abrasive wear behavior of particles with different shapes on a surface. In this work, an abrasive wheel made of silicon carbide was utilized to evaluate wear properties of specimens progressively over 5000 cycles. This experiment focused on testing two series of specimens to determine whether a bond coat composed of nickel, chromium, aluminum, and yttrium (NiCrAlY) improved the protective behavior of the APS aluminum oxide coating. The specimens varied in topcoat thickness and were made with and without an approximately 100 µm bond coat layer. The mass of the specimens was measured at 400 cycles, 800 cycles, 3800 cycles, and 5000 cycles. Increasing thickness was found to result in higher wear for samples with and without a bond coat. Increased mass loss in samples with a bond coat was observed indicating a need for further studies on the overall impact of the use of a bond coat on the protective behavior of the coatings. To continue designing wear resistant coatings for structural protection in space missions, the multifunctional properties of the APS aluminum oxide coating will be studied. Future experiments will determine whether the APS aluminum oxide coating can protect the structures from other aspects of the harsh space environment, such as extreme temperature variations and ionizing radiation.

aluminum oxide↗
NASA NTRS2018

3D Printed Structural Core with MMOD Protection

Deep space exploration requires large habitats for both orbital and surface missions. The weight of a habitat is driven largely by its structure and future vehicles require lighter weight structures to minimize launch mass and cost. Unlike honeycomb core materials used in the past, a 3D printed core can be analyzed and optimized for specific load environments, further cutting down mass of the vehicle. Multi-functional structures can integrate features into the primary structure that are traditionally added mass. MMOD (Micro Meteor and Orbital Debris) protection, for example, can be integrated directly into the primary structure of a habitat. This minimizes the mass of the structure and eliminates the need for additional MMOD layers and attachment hardware. This project seeks to develop 3D printed structural core that can be optimized for flights loads and provide integrated MMOD protection.

Hagen, Richard↗
NASA NTRS2008

Structural Analysis of Lightning Protection System for New Launch Vehicle

This project includes the design and specification of a lightning protection system for Launch Complex 39 B (LC39B) at Kennedy Space Center, FL in support of the Constellation Program. The purpose of the lightning protection system is to protect the Crew Launch Vehicle (CLV) or Cargo Launch Vehicle (CaLV) and associated launch equipment from direct lightning strikes during launch processing and other activities prior to flight. The design includes a three-tower, overhead catenary wire system to protect the vehicle and equipment on LC39B as described in the study that preceded this design effort: KSC-DX-8234 "Study: Construct Lightning Protection System LC3 9B". The study was a collaborative effort between Reynolds, Smith, and Hills (RS&H) and ASRC Aerospace (ASRC), where ASRC was responsible for the theoretical design and risk analysis of the lightning protection system and RS&H was responsible for the development of the civil and structural components; the mechanical systems; the electrical and grounding systems; and the siting of the lightning protection system. The study determined that a triangular network of overhead catenary cables and down conductors supported by three triangular free-standing towers approximately 594 ft tall (each equipped with a man lift, ladder, electrical systems, and communications systems) would provide a level of lightning protection for the Constellation Program CLV and CaLV on Launch Pad 39B that exceeds the design requirements.

Cope, Anne↗
NASA NTRS1977

Protection of cooled blades of complex internal structure

The problem of general protection of cooled blades of complex internal structure was solved by a method called SF technique which makes possible the protection of both external and internal surfaces, as well as those of the orifices of cooling air, whatever their diameter. The SF method is most often applied in the case of pack process, at controlled or high activity; it can be of use on previously uncoated parts, but also on pieces already coated by a thermochemical, chemical or PVD method. The respective thickness of external and internal coatings may be precisely predetermined, no parasitic particle being liable to remain inside the parts after application of the protecting treatment. Results obtained to date by application of this method are illustrated by the presentation and examination of a various selection of advanced turbo engines.

Glamiche, P.↗
NASA NTRS1976

Bibliography of information on mechanics of structural failure (hydrogen embrittlement, protective coatings, composite materials, NDE)

This bibliography is comprised of approximately 1,600 reference citations related to four problem areas in the mechanics of failure in aerospace structures. The bibliography represents a search of the literature published in the period 1962-1976, the effort being largely limited to documents published in the United States. Listings are subdivided into the four problem areas: Hydrogen Embrittlement; Protective Coatings; Composite Materials; and Nondestructive Evaluation. An author index is included.

Carpenter, J. L., Jr.↗
NASA NTRS1971

Intumescence: An in situ approach to thermal protection

The thermal protection of flammable structures with intumescent protective coatings is discussed. Various materials which have demonstrated an ability to provide protection through intumecence are described. Materials tests for intumescent coatings are presented and physical properties of various materials are included.

Fohlen, G. M.↗
NASA NTRS1972

Structural design aspects of reusable surface insulation thermal protection systems.

Low density fiber ceramic materials coated with refractory ceramics meet the requirements of reusable low weight thermal protection systems. The structural characteristics of this class of material impose unique design and analysis requirements on the application to spacecraft structural elements. Finite element type stress analysis techniques are required to adequately predict the structural response of the system. Parametric analyses have been performed to determine the response of the system to variations in geometry, and to thermal and structural load conditions. Sensitivity of coating, insulation and attachment stresses are presented and critical failure modes are identified.

Michalak, R. J.↗
NASA NTRS1996

Analysis of Thick Sandwich Shells with Embedded Ceramic Tiles

The Composite Armored Vehicle (CAV) is an advanced technology demonstrator of an all-composite ground combat vehicle. The CAV upper hull is made of a tough light-weight S2-glass/epoxy laminate with embedded ceramic tiles that serve as armor. The tiles are bonded to a rubber mat with a carefully selected, highly viscoelastic adhesive. The integration of armor and structure offers an efficient combination of ballistic protection and structural performance. The analysis of this anisotropic construction, with its inherent discontinuous and periodic nature, however, poses several challenges. The present paper describes a shell-based 'element-layering' technique that properly accounts for these effects and for the concentrated transverse shear flexibility in the rubber mat. One of the most important advantages of the element-layering technique over advanced higher-order elements is that it is based on conventional elements. This advantage allows the models to be portable to other structural analysis codes, a prerequisite in a program that involves the computational facilities of several manufacturers and government laboratories. The element-layering technique was implemented into an auto-layering program that automatically transforms a conventional shell model into a multi-layered model. The effects of tile layer homogenization, tile placement patterns, and tile gap size on the analysis results are described.

Davila, Carlos G.↗
NASA NTRS1997

High-Flux, High-Temperature Thermal Vacuum Qualification Testing of a Solar Receiver Aperture Shield

As part of the International Space Station (ISS) Phase 1 program, NASA Lewis Research Center (LERC) and the Russian Space Agency (RSA) teamed together to design, build and flight test the world's first orbital Solar Dynamic Power System (SDPS) on the Russian space station Mir. The Solar Dynamic Flight Demonstration (SDFD) program was to operate a nominal 2 kWe SDPS on Mir for a period up to 1-year starting in late 1997. Unfortunately, the SDFD mission was demanifested from the ISS phase 1 shuttle program in early 1996. However, substantial flight hardware and prototypical flight hardware was built including a heat receiver and aperture shield. The aperture shield comprises the front face of the cylindrical cavity heat receiver and is located at the focal plane of the solar concentrator. It is constructed of a stainless steel plate with a 1-m outside diameter, a 0.24-m inside diameter and covered with high-temperature, refractory metal Multi-Foil Insulation (MFI). The aperture shield must minimize heat loss from the receiver cavity, provide a stiff, high strength structure to accommodate shuttle launch loads and protect receiver structures from highly concentrated solar fluxes during concentrator off-pointing events. To satisfy Mir operational safety protocols, the aperture shield was required to accommodate direct impingement of the intensely concentrated solar image for a 1-hour period. To verify thermal-structural durability under the anticipated high-flux, high-temperature loading, an aperture shield test article was constructed and underwent a series of two tests in a large thermal vacuum chamber configured with a reflective, point-focus solar concentrator and a solar simulator. The test article was positioned near the focal plane and exposed to concentrated solar flux for a period of 1-hour. In the first test, a near equilibrium temperature of 1862 K was attained in the center of the shield hot spot. In the second test, with increased incident flux, a near equilibrium temperature of 2072 K was achieved. The aperture shield sustained no visible damage as a result of the exposures. This paper describes the aperture shield thermal-vacuum qualification test program including the test article, test facility, procedures, data collection, test success criteria, results and conclusions.

Kerslake, Thomas W.↗
NASA NTRS1976

A comparison of spacecraft penetration hazards due to meteoroids and manmade earth-orbiting objects

The ability of a typical double-walled spacecraft structure to protect against penetration by high-velocity incident objects is reviewed. The hazards presented by meteoroids are compared to the current and potential hazards due to manmade orbiting objects. It is shown that the nature of the meteoroid number-mass relationship makes adequate protection for large space facilities a conceptually straightforward structural problem. The present level of manmade orbiting objects (an estimated 10,000 in early 1975) does not pose an unacceptable risk to manned space operations proposed for the near future, but it does produce penetration probabilities in the range of 1-10 percent for a 100-m diameter sphere in orbit for 1,000 days. The number-size distribution of manmade objects is such that adequate protection is difficult to achieve for large permanent space facilities, to the extent that future restrictions on such facilities may result if the growth of orbiting objects continues at its historical rate.

Brooks, D. R.↗
NASA NTRS1991

NASA/USRA advanced design program activity 1990/1991

Four problems were defined which had aspects which would be reasonably assigned to an interdisciplinary design team. The design problems are: (1) design of a thermal shield for a lunar telescope (thermal protection for a lunar telescope); (2) selenotextile shielding structure (a structure to protect a lunar habitat from intense solar radiation of tubes of woven polytetrafluoroethylene coated fiberglass fabric); (3) pneumatically assisted elbow joint design for the NASA Zero-prebreathe suit (will allow astronauts to make the transition from a high pressure internal environment to a lower pressure suit without spending time in an air lock); and (4) electrochemical system to power assist an astronaut's finger joints (assist in the movement of an astronaut's distal and proximal interphalangeal finger joints).

Dorrity, J. Lewis↗
NASA NTRS1992

Enhanced softgoods structures for spacesuit micrometeoroid/debris protective systems

A lightweight, flexible thermal micrometeoroid garment (TMG) design for enhanced space suit micrometeoroid/debris (M/D) protection is described. It will consist of an outer layer comprised of orthofabric, multilayers of aluminized Mylar, and a layer of silicone rubber loaded with micron sized particles of tungsten. The shield layers would fragment and/or vaporize the M/D projectile while the backup sheet would stop the resultant debris cloud.

Remington, Brian↗
NASA NTRS2019

Electron Beam Welding of Pure Tungsten Hex Cans for Nuclear Thermal Propulsion Engines

Nuclear thermal propulsion (NTP) is an in-space propulsion method currently being developed at the NASA Marshall Space Flight Center (MSFC). NTP systems are a high specific impulse (750–1,100 s), high thrust (15,000–250,000 lbf ) method of propulsion which have the potential to allow for faster transit times when optimizing for high ΔV. In the nuclear rocket engine, the heat from the nuclear fission reaction is transferred to a low molecular mass propellant (such as hydrogen). Hot propellant is expanded through a nozzle to generate thrust. Development of ceramic metal (cermet) fuel systems for NTP applications is currently ongoing at MSFC. In cermet fuel systems, ceramic fissile fuel particles such as uranium nitride or uranium dioxide are dispersed within a net-shaped, high-density structural matrix. The composite material is cladded by a protective metal structure to make up an NTP fuel element. Cladding materials must be able to withstand the demanding operating conditions required of the engine as well as retain a hermetic seal to allow for retention of fuel element structural integrity, prevent hydrogen attack or migration of the ceramic fuel, and limit release of fission products during operation. For NTP applications, tungsten is a prime material for both the metal matrix and cladding in cermet fuel systems because of its high melting point, high temperature strength, and compatibility with hot hydrogen. If a weld in tungsten with the capability of holding a hermetic seal is achievable, tungsten becomes a strong candidate for NTP applications. This Technical Memorandum focuses on determining the weldability of pure tungsten using electron beam welding (EBW). Tungsten appears well suited for NTP applications, but it has a high ductile to brittle transition temperature (DBTT) dependent upon chemical composition, structure/stress distribution, and mechanical conditions. Therefore, it is highly subject to brittle fracture. Because of its high susceptibility to brittle fracture, it is very difficult to weld. EBW was chosen for joining pure tungsten because of its low heat input compared to gas tungsten arc welding. Reduced heat input can be directly correlated with an increase in ductility of a tungsten weld. EBW is a high energy density welding process in which a stream of electrons penetrates a weld joint in a deep, narrow spike in contrast to a broad gas tungsten arc weld pool. The investigation initially focused on EBW of tungsten plates of both 0.01 in and 0.03 in thickness to determine if EBW could weld pure tungsten without the presence of visual defects—particularly cracking—in the welds. Variation in the weld procedure and post-weld heat treatment (PWHT) was used to improve the surface appearance of flat EBWs on a pure tungsten sheet. The investigation moved on to weld 0.05-in-thick hexagonal tungsten cans with a weld joint thickness of 0.025 in. The goal for welding the pure tungsten hex cans was to avoid any visual surface defects and generate a weld capable of a hermetic seal. This proved difficult. Cold welds commonly exhibited porosity that leaked air. Hot welds exhibited cracks, typically observed immediately after welding. Later welds were preheated to increase ductility and decrease the likelihood of through-thickness cracking. PWHT was used to arrest microcrack growth both in the flat weld samples and hexagonal weld samples.

Courtright, Z. S.↗
NASA NTRS1978

A method for determining structural properties of RCC thermal protection material

A method was developed for evaluation and prediction of effects of oxidation of the graphitic substrate on structural properties of Reinforced Carbon-Carbon (RCC) thermal protection material. Test specimens of RCC material were exposed to successive periods of convective heating in a plasma-jet facility to simulate the chemical reactions of Shuttle atmospheric entry. After each period of testing, the test specimen mass loss and performance in a nondestructive flexure test were determined. A computational model of the RCC specimen was developed for the NASA Structural Analysis (NASTRAN) program and validated by comparison of calculated and experimental results of flexure tests. The elastic moduli and ultimate loads in tension and compression were then computed for various levels of substrate oxidation.

Wakefield, R. M.↗