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NASA NTRS2004

Experimental Aerothermodynamics In Support Of The Columbia Accident Investigation

The technical foundation for the most probable damage scenario reported in the Columbia Accident Investigation Board's final report was largely derived from synergistic aerodynamic/aerothermodynamic wind tunnel measurements and inviscid predictions made at NASA Langley Research Center and later corroborated with engineering analysis, high fidelity numerical viscous simulations, and foam impact testing near the close of the investigation. This report provides an overview of the hypersonic aerothermodynamic wind tunnel program conducted at NASA Langley and illustrates how the ground-based heating measurements provided early insight that guided the direction and utilization of agency resources in support of the investigation. Global surface heat transfer mappings, surface streamline patterns, and shock shapes were measured on 0.0075 scale models of the Orbiter configuration with and without postulated damage to the thermal protection system. Test parametrics include angle of attack from 38 to 42 degs, sideslip angles of 38 to 42 degs, sideslip angles of plus or minus 1 deg, Reynolds numbers based upon model length from 0.05 x 10(exp 6) to 6.5 x 10(exp 6), and normal shock density ratios of 5 (Mach 6 Air) and 12 (Mach 6 CF4). The primary objective of the testing was to provide surface heating characteristics on scaled Orbiter models with outer mold line perturbations to simulate various forms of localized surface damage to the thermal protection system. Initial experimental testing conducted within two weeks of the accident simulated a broad spectrum of thermal protection system damage to the Orbiter windward surface and was used to refute several hypothesized forms of thermal protection system damage, which included gouges in the windward thermal protection system tiles, breaches through the wing new the main landing gear door, and protuberances along the wing leading edge that produced asymmetric boundary layer transition. As the forensic phase of the investigation developed and the condition of recovered debris was examined, increasing emphasis was placed on identifying wing leading edge damage (partially and fully missing reinforced carbon-carbon panels, and eventually holes in the wing leading edge with venting to the wing upper surface) that produced off-nominal heating trends consistent with extracted Orbiter flight recorder temperature data.

Horvath, Thomas J.↗

NASA NTRS1996

Mechanism of cyanoacetylene photochemistry at 185 and 254 nm

The role of cyanoacetylene (HC3N) in the atmospheric photochemistry of Titan and its relevance to polymer formation are discussed. Investigation of the relative light absorption of HC3N, acetylene (C2H2), and diacetylene (C4H2) revealed that HC3N is an important absorber of UV light in the 205- to 225-nanometer wavelength region in Titan's polar regions. Laboratory studies established that photolysis of C2H2 initiates the polymerization of HC3N even though the HC3N is not absorbing the UV light. Quantum yield measurements establish that HC3N is 2-5 times as reactive as C2H2 for polymer formation. Photolysis of HC3N with 185-nanometer light in the presence of N2, H2, Ar, or CF4 results in a decrease in the yield of 1,3,5-tricyanobenzene (1,3,5-tcb), while photolysis in the presence of CH4, C2H6, or n-C4H10 results in an increase in 1,3,5-tcb. The rate of loss of HC3N is increased by all gases except H2, where it is unchanged. It was not possible to detect 1,3,5-tcb as a photoproduct when the partial pressure of HC3N was decreased to 1 torr. Photolysis of HC3N with 254-nanometer light in the presence of H2 or N2 results in the formation of 1,2,4-tcb, while photolysis in the presence of CH4, C2H6, or n-C4H10 results in the formation of increasing amounts of 1,3,5-tcb. Mechanisms for the formation of polymers are presented.

Non-NASA Center↗

NASA NTRS1997

Overview of X-38 Hypersonic Wind Tunnel Data and Comparison with Numerical Results

A NASA team of engineers has been organized to design a crew return vehicle for returning International Space Station crew members from orbit. The hypersonic characteristics of this X-23/X-2&4 derived crew return vehicle (designated X-38) are being evaluated in various wind tunnels in support of this effort. Aerodynamic data has been acquired in three NASA hypersonic facilities at Mach 20, and Mach 6. Computational Fluid Dynamics tools have been applied at the appropriate wind tunnel conditions to make comparisons with portions of this data. Experimental data from the Mach 6 Air and CF4 facilities illustrate a net positive pitching moment increment due to density ratio, as well as increased elevon effectiveness. Chemical nonequilibrium computational fluid dynamics solutions at flight conditions reinforce this conclusion.

Campbell, Charles H.↗

NASA NTRS1993

An Experimental Parametric Study of Geometric, Reynolds Number, and Ratio of Specific Heats Effects in Three-Dimensional Sidewall Compression Scramjet Inlets at Mach 6

Since mission profiles for airbreathing hypersonic vehicles such as the National Aero-Space Plane include single-stage-to-orbit requirements, real gas effects may become important with respect to engine performance. The effects of the decrease in the ratio of specific heats have been investigated in generic three-dimensional sidewall compression scramjet inlets with leading-edge sweep angles of 30 and 70 degrees. The effects of a decrease in ratio of specific heats were seen by comparing data from two facilities in two test gases: in the Langley Mach 6 CF4 Tunnel in tetrafluoromethane (where gamma=1.22) and in the Langley 15-Inch Mach 6 Air Tunnel in perfect gas air (where gamma=1.4). In addition to the simulated real gas effects, the parametric effects of cowl position, contraction ratio, leading-edge sweep, and Reynolds number were investigated in the 15-Inch Mach 6 Air Tunnel. The models were instrumented with a total of 45 static pressure orifices distributed on the sidewalls and baseplate. Surface streamline patterns were examined via oil flow, and schlieren videos were made of the external flow field. The results of these tests have significant implications to ground based testing of inlets in facilities which do not operate at flight enthalpies.

Holland, Scott D.↗

NASA NTRS2005

Downstream Effects on Orbiter Leeside Flow Separation for Hypersonic Flows

Discrepancies between experiment and computation for shuttle leeside flow separation, which came to light in the Columbia accident investigation, are resolved. Tests were run in the Langley Research Center 20-Inch Hypersonic CF4 Tunnel with a baseline orbiter model and two extended trailing edge models. The extended trailing edges altered the wing leeside separation lines, moving the lines toward the fuselage, proving that wing trailing edge modeling does affect the orbiter leeside flow. Computations were then made with a wake grid. These calculations more closely matched baseline experiments. Thus, the present findings demonstrate that it is imperative to include the wake flow domain in CFD calculations in order to accurately predict leeside flow separation for hypersonic vehicles at high angles of attack.

Buck, Gregory M.↗

NASA NTRS2006

Testing of Flexible Ballutes in Hypersonic Wind Tunnels for Planetary Aerocapture

Studies were conducted for the In-Space Propulsion (ISP) Ultralightweight Ballute Technology Development Program to increase the technical readiness level of inflatable decelerator systems for planetary aerocapture. The present experimental study was conducted to develop the capability for testing lightweight, flexible materials in hypersonic facilities. The primary objectives were to evaluate advanced polymer film materials in a high-temperature, high-speed flow environment and provide experimental data for comparisons with fluid-structure interaction modeling tools. Experimental testing was conducted in the Langley Aerothermodynamics Laboratory 20-Inch Hypersonic CF4 and 31-Inch Mach 10 Air blowdown wind tunnels. Quantitative flexure measurements were made for 60 degree half angle afterbody-attached ballutes, in which polyimide films (1-mil and 3-mil thick) were clamped between a 1/2-inch diameter disk and a base ring (4-inch and 6-inch diameters). Deflection measurements were made using a parallel light silhouette of the film surface through an existing schlieren optical system. The purpose of this paper is to discuss these results as well as free-flying testing techniques being developed for both an afterbody-attached and trailing toroidal ballute configuration to determine dynamic fluid-structural stability. Methods for measuring polymer film temperature were also explored using both temperature sensitive paints (for up to 370 C) and laser-etched thin-film gages.

Buck, Gregory M.↗

NASA NTRS2006

Shuttle Damage/Repair from the Perspective of Hypersonic Boundary Layer Transition - Experimental Results

An overview is provided of the experimental wind tunnel program conducted at the NASA Langley Research Center Aerothermodynamics Laboratory in support of an agency-wide effort to prepare the Shuttle Orbiter for Return-to-Flight. The effect of an isolated protuberance and an isolated rectangular cavity on hypersonic boundary layer transition onset on the windward surface of the Shuttle Orbiter has been experimentally characterized. These experimental studies were initiated to provide a protuberance and cavity effects database for developing hypersonic transition criteria to support on-orbit disposition of thermal protection system damage or repair. In addition, a synergistic experimental investigation was undertaken to assess the impact of an isolated mass-flow entrainment source (simulating pyrolysis/outgassing from a proposed tile repair material) on boundary layer transition. A brief review of the relevant literature regarding hypersonic boundary layer transition induced from cavities and localized mass addition from ablation is presented. Boundary layer transition results were obtained using 0.0075-scale Orbiter models with simulated tile damage (rectangular cavities) of varying length, width, and depth and simulated tile damage or repair (protuberances) of varying height. Cavity and mass addition effects were assessed at a fixed location (x/L = 0.3) along the model centerline in a region of near zero pressure gradient. Cavity length-to-depth ratio was systematically varied from 2.5 to 17.7 and length-to-width ratio of 1 to 8.5. Cavity depth-to-local boundary layer thickness ranged from 0.5 to 4.8. Protuberances were located at several sites along the centerline and port/starboard attachment lines along the chine and wing leading edge. Protuberance height-to-boundary layer thickness was varied from approximately 0.2 to 1.1. Global heat transfer images and heating distributions of the Orbiter windward surface using phosphor thermography were used to infer the state of the boundary layer (laminar, transitional, or turbulent). Test parametrics include angles-of-attack of 30 deg and 40 deg, sideslip angle of 0 deg, freestream Reynolds numbers from 0.02x106 to 7.3x106 per foot, edge-to-wall temperature ratio from 0.4 to 0.8, and normal shock density ratios of approximately 5.3, 6.0, and 12 in Mach 6 air, Mach 10 air, and Mach 6 CF4, respectively. Testing to simulate the effects of ablation from a proposed tile repair concept indicated that transition was not a concern. The experimental protuberance and cavity databases highlighted in this report were used to formulate boundary layer transition correlations that were an integral part of an analytical process to disposition observed Orbiter TPS damage during STS- 114.

Horvath, Thomas J.↗

NASA NTRS2007

Testing of Flexible Ballutes in Hypersonic Wind Tunnels for Planetary Aerocapture

Studies were conducted for the In-Space Propulsion (ISP) Ultralightweight Ballute Technology Development Program to increase the technical readiness level of inflatable decelerator systems for planetary aerocapture. The present experimental study was conducted to develop the capability for testing lightweight, flexible materials in hypersonic facilities. The primary objectives were to evaluate advanced polymer film materials in a high-temperature, high-speed flow environment and provide experimental data for comparisons with fluid-structure interaction modeling tools. Experimental testing was conducted in the Langley Aerothermodynamics Laboratory 20-Inch Hypersonic CF4 and 31-Inch Mach 10 Air blowdown wind tunnels. Quantitative flexure measurements were made for 60 degree half angle afterbody-attached ballutes, in which polyimide films (1-mil and 3- mil thick) were clamped between a 1/2-inch diameter disk and a base ring (4-inch and 6-inch diameters). Deflection measurements were made using a parallel light silhouette of the film surface through an existing schlieren optical system. The purpose of this paper is to discuss these results as well as free-flying testing techniques being developed for both an afterbody-attached and trailing toroidal ballute configuration to determine dynamic fluid-structural stability. Methods for measuring polymer film temperature were also explored using both temperature sensitive paints (for up to 370 C) and laser-etched thin-film gages.

Buck, Gregory M.↗

NASA NTRS2009

Version 2 of the Protuberance Correlations for the Shuttle-Orbiter Boundary Layer Transition Tool

Orbiter-specific transition data, acquired in four ground-based facilities (LaRC 20-Inch Mach 6 Air Tunnel, LaRC 31-Inch Mach 10 Air Tunnel, LaRC 20-Inch Mach 6 CF4 Tunnel, and CUBRC LENS-I Shock Tunnel) with three wind tunnel model scales (0.75, 0.90, and 1.8%) and from Orbiter historical flight data, have been analyzed to improve a pre-existing engineering tool for reentry transition prediction on the windward side of the Orbiter. Boundary layer transition (BLT) engineering correlations for transition induced by isolated protuberances are presented using a laminar Navier-Stokes (N-S) database to provide the relevant boundary-layer properties. It is demonstrated that the earlier version of the BLT correlation that had been developed using parameters derived from an engineering boundary-layer code has improved data collapse when developed with the N-S database. Of the new correlations examined, the proposed correlation 5, based on boundary-layer edge and wall properties, was found to provide the best overall correlation metrics when the entire database is employed. The second independent correlation (proposed correlation 7) selected is based on properties within the boundary layer at the protuberance height. The Aeroheating Panel selected a process to derive the recommended coefficients for Version 2 of the BLT Tool. The assumptions and limitations of the recommended protuberance BLT Tool V.2 are presented.

King, Rudolph A.↗

NASA NTRS2006

Selective Plasma Deposition of Fluorocarbon Films on SAMs

A dry plasma process has been demonstrated to be useful for the selective modification of self-assembled monolayers (SAMs) of alkanethiolates. These SAMs are used, during the fabrication of semiconductor electronic devices, as etch masks on gold layers that are destined to be patterned and incorporated into the devices. The selective modification involves the formation of fluorocarbon films that render the SAMs more effective in protecting the masked areas of the gold against etching by a potassium iodide (KI) solution. This modification can be utilized, not only in the fabrication of single electronic devices but also in the fabrication of integrated circuits, microelectromechanical systems, and circuit boards. In the steps that precede the dry plasma process, a silicon mold in the desired pattern is fabricated by standard photolithographic techniques. A stamp is then made by casting polydimethylsiloxane (commonly known as silicone rubber) in the mold. The stamp is coated with an alkanethiol solution, then the stamp is pressed on the gold layer of a device to be fabricated in order to deposit the alkanethiol to form an alkanethiolate SAM in the desired pattern (see figure). Next, the workpiece is exposed to a radio-frequency plasma generated from a mixture of CF4 and H2 gases. After this plasma treatment, the SAM is found to be modified, while the exposed areas of gold remain unchanged. This dry plasma process offers the potential for forming masks superior to those formed in a prior wet etching process. Among the advantages over the wet etching process are greater selectivity, fewer pin holes in the masks, and less nonuniformity of the masks. The fluorocarbon films formed in this way may also be useful as intermediate layers for subsequent fabrication steps and as dielectric layers to be incorporated into finished products.

Crain, Mark M., III↗

NASA NTRS2011

Supersonic/Hypersonic Correlations for In-Cavity Transition and Heating Augmentation

Laminar-entry cavity heating data with a non-laminar boundary layer exit flow have been retrieved from the database developed at Mach 6 and 10 in air on large flat plate models for the Space Shuttle Return-To-Flight Program. Building on previously published fully laminar and fully turbulent analysis methods, new descriptive correlations of the in-cavity floor-averaged heating and endwall maximum heating have been developed for transitional-to-turbulent exit flow. These new local-cavity correlations provide the expected flow and geometry conditions for transition onset; they provide the incremental heating augmentation induced by transitional flow; and, they provide the transitional-to-turbulent exit cavity length. Furthermore, they provide an upper application limit for the previously developed fully-laminar heating correlations. An example is provided that demonstrates simplicity of application. Heating augmentation factors of 12 and 3 above the fully laminar values are shown to exist on the cavity floor and endwall, respectively, if the flow exits in fully tripped-to-turbulent boundary layer state. Cavity floor heating data in geometries installed on the windward surface of 0.075-scale Shuttle wind tunnel models have also been retrieved from the boundary layer transition database developed for the Return-To-Flight Program. These data were independently acquired at Mach 6 and Mach 10 in air, and at Mach 6 in CF4. The correlation parameters for the floor-averaged heating have been developed and they offer an exceptionally positive comparison to previously developed laminar-cavity heating correlations. Non-laminar increments have been extracted from the Shuttle data and they fall on the newly developed transitional in-cavity correlations, and they are bounded by the 95% correlation prediction limits. Because the ratio of specific heats changes along the re-entry trajectory, turning angle into a cavity and boundary layer flow properties may be affected, raising concerns regarding the application validity of the heating augmentation predictions.

Everhart, Joel L.↗

NASA NTRS2003

Process for Smoothing an Si Substrate after Etching of SiO2

A reactive-ion etching (RIE) process for smoothing a silicon substrate has been devised. The process is especially useful for smoothing those silicon areas that have been exposed by etching a pattern of holes in a layer of silicon dioxide that covers the substrate. Applications in which one could utilize smooth silicon surfaces like those produced by this process include fabrication of optical waveguides, epitaxial deposition of silicon on selected areas of silicon substrates, and preparation of silicon substrates for deposition of adherent metal layers. During etching away of a layer of SiO2 that covers an Si substrate, a polymer becomes deposited on the substrate, and the substrate surface becomes rough (roughness height approximately equal to 50 nm) as a result of over-etching or of deposition of the polymer. While it is possible to smooth a silicon substrate by wet chemical etching, the undesired consequences of wet chemical etching can include compromising the integrity of the SiO2 sidewalls and undercutting of the adjacent areas of the silicon dioxide that are meant to be left intact. The present RIE process results in anisotropic etching that removes the polymer and reduces height of roughness of the silicon substrate to less than 10 nm while leaving the SiO2 sidewalls intact and vertical. Control over substrate versus sidewall etching (in particular, preferential etching of the substrate) is achieved through selection of process parameters, including gas flow, power, and pressure. Such control is not uniformly and repeatably achievable in wet chemical etching. The recipe for the present RIE process is the following: Etch 1 - A mixture of CF4 and O2 gases flowing at rates of 25 to 75 and 75 to 125 standard cubic centimeters per minute (stdcm3/min), respectively; power between 44 and 55 W; and pressure between 45 and 55 mtorr (between 6.0 and 7.3 Pa). The etch rate lies between approximately equal to 3 and approximately equal to 6 nm/minute. Etch 2 - O2 gas flowing at 75 to 125 stdcm3/min, power between 44 and 55 W, and pressure between 50 and 100 mtorr (between 6.7 and 13.3 Pa).

Turner, Tasha↗

NASA NTRS2007

Single-Shot Rotational Raman Thermometry for Turbulent Flames Using a Low-Resolution Bandwidth Technique

An alternative optical thermometry technique that utilizes the low-resolution (order 10(exp 1)/cm) pure-rotational spontaneous Raman scattering of air is developed to aid single-shot multiscalar measurements in turbulent combustion studies. Temperature measurements are realized by correlating the measured envelope bandwidth of the pure-rotational manifold of the N2/O2 spectrum with a theoretical prediction of a species-weighted bandwidth. By coupling this thermometry technique with conventional vibrational Raman scattering for species determination, we demonstrate quantitative spatially resolved, single-shot measurements of the temperature and fuel/oxidizer concentrations in a high-pressure turbulent Cf4-air flame. Our technique provides not only an effective means of validating other temperature measurement methods, but also serves as a secondary thermometry technique in cases where the anti-Stokes vibrational N2 Raman signals are too low for a conventional vibrational temperature analysis.

Kojima, Jun↗

NASA NTRSDate not supplied

TPSAS-NF1676L-13013-DND

Description, capabilities and utilization of the NASA Langley Aerothermodynamics Laboratory (LAL) are presented. The LAL consists of four hypersonic, blow-down-to-vacuum wind tunnels that collectively provide a range of Mach number from 6 to 10 (18 simulation), unit Reynolds number from 0.05 to 8 million per foot and, most importantly for blunt configurations, normal shock density ratio from 4 to 12. These wide ranges of hypersonic simulation parameters are due, in part, to the use of two different test gases (air and tetrafluoromethane, CF4), thereby making the facilities unique. The complex represents half of the conventional (as opposed to impulse) -type hypersonic wind tunnels operational in this country. LAL facilities are used to assess and optimize the hypersonic aerodynamic performance and aeroheating characteristics of aerospace vehicle concepts and to provide benchmark aerodynamic/aeroheating data for generating the flight aerodynamic databook and final design of the thermal protection system (TPS). Modifications and enhancements of LAL hardware components and instrumentation have been pursued to increase capability, reliability, and productivity in support of programmatic goals. The facilities are utilized to generate essentially all of the experimental hypersonic aerodynamic and aeroheating information for high-priority, fast-paced Agency programs and were a major contributor to the Shuttle Columbia Accident Investigation, space shuttle Return-to-Flight program and Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project. The LAL has also contributed to the development of the Orion Crew Exploration Vehicle, Ares launch system, Mars Science Laboratory, Genesis Sample Return Capsule and supported DOD programs including HIFiRE, X-37, Falcon HTV-2 and X-51A.

John R Micol↗

NASA NTRS2023

An Improved Hf Vapor Etching Apparatus for Stardust Particle Extraction

Introduction: The NASA Stardust mission captured thousands of particles from the Jupiter-family comet 81P/Wild 2 in a collector composed of aluminum foil and blocks of silica aerogel [1]. To date, most Wild 2 particles available for study are relatively large and coherent particles extracted individually from the ends of hollow, carrot-shaped impact tracks produced during impact into aerogel. However, >65% of the impacting mass can be found in the ‘bulb’ of the track, including nearly all of the <1 μm size fraction [2]. This fraction contains organic-rich material and is likely to include presolar grains, representing a critical opportunity to constrain the organic and presolar inventory of primitive outer solar system materials. However, the small size and susceptibility of this fraction to melting or alteration during capture poses significant analytical challenges. Previous attempts to extract and concentrate fine-grained material from the bulb of Stardust tracks have attempted to develop techniques that efficiently destroy aerogel and leave impactor particles relatively unharmed. The low density and high porosity of silica aerogel makes it more susceptible to attack by etching with hydrofluoric acid (HF) [3] or CF4 plasma ashing [4] than collected cometary silicates. Previous studies of HF vapor etching used HF solutions varying between 5 to 49% and noted that at high concentrations and etch rates, a liquid droplet was produced according to the etching reaction 4HF + SiO2 → SiF4 (g) + 2H2O [3]. SiF4 readily decomposes into HF and silicic acid in water, which has the potential to alter the freed cometary silicates. The plasma ashing technique avoids production of a liquid droplet and minimizes damage to embedded silicates but requires specialized equipment [4]. In this abstract, we present recent improvements to the HF etching procedure with the aim of constructing an etching chamber capable of slowly etching silica aerogel using small quantities of dilute HF. The etching chamber can be assembled using readily available materials.

Stardust↗