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NASA NTRS2014

The Status of Spacecraft Bus and Platform Technology Development Under the NASA ISPT Program

The In-Space Propulsion Technology (ISPT) program is developing spacecraft bus and platform technologies that will enable or enhance NASA robotic science missions. The ISPT program is currently developing technology in three areas that include Propulsion System Technologies, Entry Vehicle Technologies, and Systems Mission Analysis. ISPTs propulsion technologies include: 1) NASAs Evolutionary Xenon Thruster (NEXT) ion propulsion system, a 0.6-7 kW throttle-able gridded ion system; 2) a Hall-effect electric propulsion (HEP) system for sample return and low cost missions; 3) the Advanced Xenon Flow Control System (AXFS); ultra-lightweight propellant tank technologies (ULTT); and propulsion technologies for a Mars Ascent Vehicle (MAV). The AXFS and ULTT are two component technologies being developed with nearer-term flight infusion in mind, whereas NEXT and the HEP are being developed as EP systems. ISPTs entry vehicle technologies are: 1) Aerocapture technology development with investments in a family of thermal protection system (TPS) materials and structures; guidance, navigation, and control (GNC) models of blunt-body rigid aeroshells; and aerothermal effect models; and 2) Multi-mission technologies for Earth Entry Vehicles (MMEEV) for sample return missions. The Systems Mission Analysis area is focused on developing tools and assessing the application of propulsion, entry vehicle, and spacecraft bus technologies to a wide variety of mission concepts. Several of the ISPT technologies are related to sample return missions and other spacecraft bus technology needs like: MAV propulsion, MMEEV, and electric propulsion. These technologies, as well as Aerocapture, are more vehicle and mission-focused, and present a different set of technology development challenges. These in-space propulsion technologies are applicable, and potentially enabling for future NASA Discovery, New Frontiers, Flagship and sample return missions currently under consideration. This paper provides a brief overview of the ISPT program, describing the development status and technology infusion readiness.

electric propulsion↗

NASA NTRS2018

Overview of Heatshield for Extreme Entry Environment Technology (HEEET) Project

The objective of the Heatshield for Extreme Entry Environment Technology (HEEET) projects is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. Destinations that have extreme entry environments with heat fluxes up to 5000 watts per square centimeter and pressures up to 5 atmospheres, entry environments that NASA has not flown since Pioneer-Venus and Galileo. The scope of the project is broad and can be split into roughly four areas, Manufacturing/Integration, Structural Testing and Analysis, Thermal Testing and Analysis and Documentation. Manufactruing/Integration covers from raw materials, piece part fabrication to final integration on a 1-meter base diameter 45-degree sphere cone Engineering Test Unit (ETU). A key aspect of the project was to transfer as much of the manufacturing technology to industry in preparation to support future mission infusion. The forming, infusion and machining approaches were transferred to Fiber Materials Inc. and FMI then fabricated the piece parts from which the ETU was manufactured. The base 3D-woven material consists of a dual layer weave with a high density outer layer to manage recession in the system and a lower density, lower thermal conductivity inner layer to manage the heat load. At the start of the project it was understood that due to weaving limitations the heat shield was going to be manufactured from a series of tiles. And it was recognized that the development of a seam solution that met the structural and thermal requirements of the system was going to be the most challenging aspect of the project. It was also recognized that the seam design would drive the final integration approach and therefore the integration of the ETU was kept in-house within NASA. A final seam concept has been successfully developed and implemented on the ETU and will be discussed. The structural testing and analysis covers from characterization of the different layers of the infused material as functions of weave direction and temperature, to sub-component level testing such as 4-pt bend testing at sub-ambient and elevated temperature. ETU test results are used to validate the structural models developed using the element and sub-component level tests. Given the seam has to perform both structurally and aerothermally during entry a novel 4-pt bend test fixture was developed allowing articles to be tested while the front surface is heated with a laser. These tests are intended to establish the system's structural capability during entry. A broad range of aerothermal tests (arcjet tests) are being performed to develop material response models for predicting the required TPS thickness to meet a mission's needs and to evaluate failure modes. These tests establish the capability of the system and assure robustness of the system during entry. The final aspect of the project is to develop a comprehensive Design and Data Book such that a future mission will have the information necessary to adopt the technology. This presentation will provide an overview and status of the project and describe the status of the tehnology maturation level for the inner and outer planet as well as earth entry sample return missions.

Ellerby, Don↗

NASA NTRS1994

Pressure distributions on a 0.02-scale Space Shuttle orbiter nose at Mach 21.5 in helium

Pressure distributions on a 0.02-scale model of the Space Shuttle orbiter forward fuselage were obtained in the 22-inch aerodynamic leg of the Langley Hypersonic Helium Tunnel Facility at a nominal free-stream Mach number of 21.5 and a ratio of specific heats of 1.67 for inclusion in the database of the Shuttle entry air data system (SEADS). The data were measured at model angles of attack of 0 deg to 50 deg in 5 deg increments for zero sideslip angle and at model sideslip angles of -5 deg to 5 deg for angles of attack equal to 5, 20, 35, and 40 deg. These data displayed trends similar to those observed in other wind tunnels at Mach 6 and 10 in air. Specifically noted is a shift in the location of the stagnation point at angles of attack above 15 deg; this effect did not, however, occur in flight. By comparison, the data obtained at Mach 6 in the Langley Hypersonic CF4 Tunnel, corresponding to a lower ratio of specific heats in the postshock region than those in helium and air, showed some reduction of the stagnation point shift at the higher angles of attack. The differences between flight and wind tunnel pressure distributions are believed due primarily to high-temperature gas chemistry effects in flight, which include lower effective specific heat ratios but which were not completely duplicated in the wind tunnels.

Ashby, George C., Jr.↗

NASA NTRSDate not supplied

Overview of Ablation Modeling at NASA

The ambitious scientific payload and crew delivery goals of imminent and future NASA missions are associated with challenging and complex vehicle entries. Advanced ablative Thermal Protection System (TPS) materials will be required for such missions, and, as such, a robust ablation modeling capability is critical to assessing performance by bridging the wide gap between ground testing and entry conditions. The traditional ablation modeling toolset - continuum thermal/materials response analysis - has grown recently to include high-fidelity, multi-scale, and multi-physics techniques that provide a more complete description of the rich physics and chemistry of ablation to better drive down risks related to extreme entries. The present talk provides a snapshot of ongoing NASA activities in ablation modeling, including a review of the current technical capabilities and tools at play within the Agency, the important role academia plays in supporting technical area advancements, and how such internal and external investments intersect with upcoming missions to drive down risks.

TPS↗

NASA NTRSDate not supplied

The NASA Ames Aerothermodynamics Branch (Code TSA)

The NASA Ames Aerothermodynamics Branch provides NASA with integrated modeling, simulation, and test capabilities in the areas of aerothermodynamics, shock layer radiation, and entry system design. Our core capabilities include CFD simulation for entry vehicles at hypersonic velocities, including arc jet facility flow modeling and characterization; modeling and testing of shock layer kinetics and radiation; development of flow-field diagnostic techniques; and aero- and aerothermal testing via ballistic ranges. This presentation provides a brief technical introduction to the branches work and our capabilities in these areas.

Aerothermodynamics↗

NASA NTRSDate not supplied

Overview of Ablation Modeling at NASA

The ambitious scientific payload and crew delivery goals of imminent and future NASA missions are associated with challenging and complex vehicle entries. Advanced ablative Thermal Protection System (TPS) materials will be re- quired for such missions, and, as such, a robust ablation modeling capability is critical to assessing performance by bridging the wide gap between ground testing and entry conditions. The traditional ablation modeling toolset - contin- uum thermal/materials response analysis - has grown recently to include high-fidelity, multi-scale, and multi-physics techniques that provide a more complete description of the rich physics and chemistry of ablation to better drive down risks related to extreme entries. The present talk provides a snapshot of ongoing NASA activities in ablation mod- eling, including a review of the current technical capabilities and tools at play within the Agency, the important role academia plays in supporting technical area advancements, and how such internal and external investments intersect with upcoming missions to drive down risks.

Justin Haskins↗

NASA NTRS1971

The relative effects of entry parameters on thermal protection system weight

Shielding a spacecraft from the severe thermal environment of an atmospheric entry requires a sophisticated thermal protection system (TPS). Thermal computer program models were developed for two such TPS designs proposed for the space shuttle orbiter. The multilayer systems, a reusable surface insulation TPS, and a re-radiative metallic skin TPS, were sized for a cross-section of trajectories in the entry corridor. This analysis indicates the relative influence of the entry parameters on the weight of each TPS concept. The results are summarized graphically. The trajectory variables considered were down-range, cross-range, orbit inclination, entry interface velocity and flight path angle, maximum heating rate level, angle of attack, and ballistic coefficient. Variations in cross-range and flight path angle over the ranges considered had virtually no effect on the required entry TPS weight. The TPS weight was significantly more sensitive to variations in angle of attack than to dispersions in the other trajectory considered.

Hirasaki, P. N.↗

NASA NTRSDate not supplied

Mars Sample Return Earth Entry System Woven Roughness Mach 6 Aeroheating Test

The Mars Sample Return Earth Entry System is the first entry vehicle designed for a NASA flagship mission to utilize a woven thermal protection system as well as a 52.5 degree sphere cone forebody geometry. As a result, no heritage aeroheating experimental data set exists to compare with computational predictions. In order to obtain a set of validation data for computational models, an extensive wind tunnel test campaign was funded by the Mars Sample Return Earth Entry System project. The first entry in the test campaign was completed in April of 2023, which was an investigation of turbulent heating augmentation due to woven thermal protection system roughness on the 52.5 degree Mars Sample Return - Earth Entry System vehicle forebody geometry. This test entry produced the first ever experimental aeroheating data on a 52.5 degree sphere-cone geometry as well as the first NASA experimental aeroheating data on a woven surface roughness pattern. Data obtained from this test campaign is being directly leveraged to support the NASA flight program, as experimental results are being utilized to validate the computational models which characterize the aeroheating environment that the vehicle experiences and predict turbulent surface heating levels and margins across the woven surface.

Jonathan S Cheatwood↗

NASA NTRSDate not supplied

Mars Sample Return Earth Entry System Woven Roughness Mach 6 Aeroheating Test

The Mars Sample Return Earth Entry System is the first entry vehicle designed for a NASA flagship mission to utilize a woven thermal protection system as well as a 52.5 degree sphere cone forebody geometry. As a result, no heritage aeroheating experimental data set exists to compare with computational predictions. In order to obtain a set of validation data for computational models, an extensive wind tunnel test campaign was funded by the Mars Sample Return Earth Entry System project. The first entry in the test campaign was completed in April of 2023, which was an investigation of turbulent heating augmentation due to woven thermal protection system roughness on the 52.5 degree Mars Sample Return - Earth Entry System vehicle forebody geometry. This test entry produced the first ever experimental aeroheating data on a 52.5 deg sphere-cone geometry as well as the first NASA experimental aeroheating data on a woven surface roughness pattern. Data obtained from this test campaign is being directly leveraged to support the NASA flight program, as experimental results are being utilized to validate the computational models which characterize the aeroheating environment that the vehicle experiences and predict turbulent surface heating levels and margins across the woven surface.

Jonathan Cheatwood↗

NASA NTRS1973

A roll-pitch interaction simulator and a control position command encoder for remote piloting of spin-entry research models

The Langley Research Center uses radio-controlled, scaled aircraft models to study the spin-entry characteristics of aircraft. Recent spin-entry studies required the use of an electronic proportional-control system for manipulating model control surfaces. In order to meet control system requirements, a special-purpose analog computer was designed to simulate the coupling between roll and pitch controls. A digital encoder was designed to encode the voltage analogs of control-surface position into a special pulse format for transmission to the model. This paper describes the two special developments and their relationship to the functions of the overall control system.

Meissner, C. W., Jr.↗

NASA NTRS2013

GFEChutes Lo-Fi

NASA needed to provide a software model of a parachute system for a manned re-entry vehicle. NASA has parachute codes, e.g., the Descent Simulation System (DSS), that date back to the Apollo Program. Since the space shuttle did not rely on parachutes as its primary descent control mechanism, DSS has not been maintained or incorporated into modern simulation architectures such as Osiris and Antares, which are used for new mission simulations. GFEChutes Lo-Fi is an object-oriented implementation of conventional parachute codes designed for use in modern simulation environments. The GFE (Government Furnished Equipment), low-fidelity (Lo-Fi) parachute model (GFEChutes Lo-Fi) is a software package capable of modeling the effects of multiple parachutes, deployed concurrently and/or sequentially, on a vehicle during the subsonic phase of reentry into planetary atmosphere. The term "low-fidelity" distinguishes models that represent the parachutes as simple forces acting on the vehicle, as opposed to independent aerodynamic bodies. GFEChutes Lo-Fi was created from these existing models to be clean, modular, certified as NASA Class C software, and portable, or "plug and play." The GFE Lo-Fi Chutes Model provides basic modeling capability of a sequential series of parachute activities. Actions include deploying the parachute, changing the reefing on the parachute, and cutting away the parachute. Multiple chutes can be deployed at any given time, but all chutes in that case are assumed to behave as individually isolated chutes; there is no modeling of any interactions between deployed chutes. Drag characteristics of a deployed chute are based on a coefficient of drag, the face area of the chute, and the local dynamic pressure only. The orientation of the chute is approximately modeled for purposes of obtaining torques on the vehicle, but the dynamic state of the chute as a separate entity is not integrated - the treatment is simply an approximation. The innovation in GFEChutes Lo-Fi is to use an object design that closely followed the mechanical characteristics and structure of a physical system of parachutes and their deployment mechanisms. Software objects represent the components of the system, and use of an object hierarchy allows a progression from general component outlines to specific implementations. These extra chutes were not part of the baseline deceleration sequence of drogues and mains, but still had to be simulated. The major innovation in GFEChutes Lo-Fi is the software design and architecture.

Gist, Emily↗

NASA NTRS2003

Engineering-Level Model Atmospheres For Titan and Mars

An engineering-level atmospheric model for Titan has been developed for use in NASA s systems analysis studies of aerocapture and entry, descent and landing (EDL) applications in potential missions to Titan. Analogous to highly successful Global Reference Atmospheric Models for Earth (GRAM) and Mars (Mars-GRAM), the new model is called Titan-GRAM. Like GRAM and Mars-GRAM, an important feature of Titan-GRAM is its ability to simulate quasi-random perturbations for Monte-Carlo analyses in developing guidance, navigation and control algorithms, and for thermal systems design. Titan-GRAM features and sample results will be presented. Features of Mars-GRAM especially related to EDL applications will also be presented and illustrated.

Justus, C. G.↗

NASA NTRS2013

Sabots, Obturator and Gas-In-Launch Tube Techniques for Heat Flux Models in Ballistic Ranges

For thermal protection system (heat shield) design for space vehicle entry into earth and other planetary atmospheres, it is essential to know the augmentation of the heat flux due to vehicle surface roughness. At the NASA Ames Hypervelocity Free Flight Aerodynamic Facility (HFFAF) ballistic range, a campaign of heat flux studies on rough models, using infrared camera techniques, has been initiated. Several phenomena can interfere with obtaining good heat flux data when using this measuring technique. These include leakage of the hot drive gas in the gun barrel through joints in the sabot (model carrier) to create spurious thermal imprints on the model forebody, deposition of sabot material on the model forebody, thereby changing the thermal properties of the model surface and unknown in-barrel heating of the model. This report presents developments in launch techniques to greatly reduce or eliminate these problems. The techniques include the use of obturator cups behind the launch package, enclosed versus open front sabot designs and the use of hydrogen gas in the launch tube. Attention also had to be paid to the problem of the obturator drafting behind the model and impacting the model. Of the techniques presented, the obturator cups and hydrogen in the launch tube were successful when properly implemented

obturators↗

NASA NTRSDate not supplied

Multiscale Thermal Conductivity Modeling of 3D Woven Composite Thermal Protection System Materials

Novel thermal protection systems (TPS) for re-entry and hypersonic vehicles utilize 3D woven composite materials with blended carbon filament tows (yarns) and a phenolic resin matrix. The presence of continuous carbon fibers provides superior stiffness and strength compared to legacy TPS, while the 3D weave pattern provides a great deal of design flexibility for both in-plane and through thickness thermomechanical behavior. However, modeling of 3D woven composites is notoriously complex and numerically intensive. The present investigation utilizes a unique ultra-efficient approach, known as Multiscale Recursive Micromechanics (MsRM), wherein recursive semi-analytical micromechanics methods are employed at various length scales within the composite. The MsRM approach has recently been extended to solve for the effective thermal conductivity as well as the local temperature and thermal flux fields throughout the composite. Presented model results focus on the impact of the microstructural geometry representation at each length scale on the material’s effective thermal conductivity, along with the local thermal flux and temperature fields induced in the microstructures, for a novel 3D woven TPS.

Composite↗

NASA NTRS1981

Thermal and aerothermal performance of a titanium multiwall thermal protection system

A metallic thermal protection system (TPS) concept the multiwall designed for temperature and pressure at Shuttle body point 3140 where the maximum surface temperature is approximately 811 K was tested to evaluate thermal performance and structural integrity. A two tile model of titanium multiwall and a model consisting of a low temperature reusable surface insulation (LRSI) tiles were exposed to 25 simulated thermal and pressure Shuttle entry missions. The two systems performed the same, and neither system deteriorated during the tests. It is indicated that redesign of the multiwall tiles reduces tile thickness and/or weight. A nine tile model of titanium multiwal was tested for radiant heating and aerothermodynamics. Minor design changes that improve structural integrity without having a significant impact on the thermal protection ability of the titanium multiwall TPS are identified. The capability of a titanium multiwall thermal protection system to protect an aluminum surface during a Shuttle type entry trajectory at locations on the vehicle where the maximum surface temperature is below 811 K is demonstrated.

Avery, D. E.↗

NASA NTRS1988

Shuttle Entry Air Data System (SEADS) - Optimization of preflight algorithms based on flight results

The SEADS pressure model algorithm results were tested against other sources of air data, in particular, the Shuttle Best Estimated Trajectory (BET). The algorithm basis was also tested through a comparison of flight-measured pressure distribution vs the wind tunnel database. It is concluded that the successful flight of SEADS and the subsequent analysis of the data shows good agreement between BET and SEADS air data.

Wolf, H.↗

NASA NTRS2007

Simulating Flights of Future Launch Vehicles and Spacecraft

Marshall Aerospace Vehicle Representation in C (MAVERIC) is a computer program for generic, low-to-high-fidelity simulation of the flight(s) of one or more launch vehicle(s) or spacecraft. MAVERIC is designed to accommodate multi-staged vehicles, powered serially or in parallel, with multiple engines, tanks, and cargo elements. Engines can be of jet or conventional rocket types, using either liquid or solid propellants. MAVERIC includes generic subsystem software models for propulsion systems, mass properties, reaction control systems, aerodynamic properties, guidance systems, and navigation systems. Simulations can be started at points other than liftoff. Also included are guidance-system software models that accommodate the ascent, orbit, coasting, deorbiting, entry, terminal-area-energy-management, approach, and landing phases of flight. Options to use different wind profiles and atmospheres are included. A Monte Carlo capability is provided for modeling dispersions associated with atmospheric effects (including winds), propulsion, navigation, aerodynamics, and mass properties. Failures of engines and other subsystems can be modeled. The program is written in the C programming language, which makes it possible for the program to have high degrees of modularity, reusability, and maintainability, thereby also facilitating modification for modeling new vehicles.

McCarter, James W.↗

NASA NTRSDate not supplied

Aerosciences Implications for Uranus Aerocapture

Exploration of Uranus has been indicated as the highest priority new flagship planetary science missions for NASA in the 2022 Decadal Survey. Due to Uranus’ location as the second furthest planet from the Sun, interplanetary flight times of a traditional propulsive-capture orbiter can expect to take 13-15 years to reach Uranus while requiring up to two-thirds of the launch mass budget to be allocated to propellant alone. Aerocapture presents an alternative means to capture orbit around Uranus by using aerodynamic forces generated from flight through the planetary atmosphere to decelerate to orbital insertion while reducing time in interplanetary transit time and increasing on-orbit payload mass. To date, only one spacecraft (Voyager 2) has visited Uranus, and there have been no missions which have entered its atmosphere. While knowledge of planetary entry at rocky terrestrial planets with Air (N2/O2) and CO2 dominated atmospheres has greatly advanced over the past decades with a variety of missions to learn from, the H2/He composition and much larger atmosphere of ice giants such as Uranus poses new aerosciences implications which are not fully understood. These implications must be better understood not only for aerocapture, but for planetary entry at Uranus as a whole (such as a Uranus probe, as proposed by the 2022 Decadal Survey), as well as other ice giants like Neptune. To conduct a proper analysis of aerocapture methods, aerodynamic and aerothermal analysis of flight trajectories in Uranus atmosphere are required. Previous work has investigated aerocapture at Neptune (with similar atmosphere to Uranus) using a Mid-L/D configuration. Additional previous work considers the convective heating experienced in H2/He atmospheres. The current work looks to use heritage Low-L/D configurations, adding technical depth and maturation to analysis previously performed by Girija. Atmospheric flight at ice giants presents unique challenges, including but not limited to: fidelity of atmospheric models, large entry velocities due to location in the solar system, extended flight in rarefied flow conditions due to atmospheric scale, and unusual aerodynamic flow properties specific to Uranus and Ice Giant atmospheres.

Eli Shellabarger↗