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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Contents include the following: Why ablative thermal protections - TPS. Ablative TPS chronology: strategic reentry systems, solid rocket motor nozzles, space (manned missions and planetary entry probes). Ablation mechanisms. Ablation material testing. Ablative material testing.
Feasibility of Scout launched small lifting reentry vehicle for testing materials and thermostructures of full scale reentry vehicles
The SRM propellant and polymer materials structural test program has potentially wide application to the testing and structural analysis of polymer materials and other materials generally characterized as being made of viscoelastic materials. The test program will provide a basis for characterization of the dynamic failure criteria for Solid Rocket Motor (SRM) propellant, insulation, inhibitor and liners. This experimental investigation will also endeavor to obtain a consistent complete set of materials test data. This test will be used to improve and revise the presently used theoretical math models for SRM propellant, insulators, inhibitor, liners, and O-ring seals.
The material testing results described in this paper were part of a material development program of vendor-supplied, proposed heat shield materials. The goal of this program was to develop low density, rigid material systems with an appreciable weight savings over phenolic-impregnated carbon ablator (PICA) while improving material response performance. New technologies, such as PICA-like materials in honeycomb or materials with variable density through-the-thickness were tested. The material testing took place at the Wright-Patterson Air Force Base Laser Hardened Materials Laboratory (LHMEL) using a 10.6 micron CO2 laser operating with the test articles immersed in a nitrogen-gas environment at 1 atmosphere pressure. Test measurements included thermocouple readings of in-depth temperatures, pyrometer readings of surface temperatures, weight scale readings of mass loss, and sectioned-sample readings of char depth. Two laser exposures were applied. The first exposure was at an irradiance of 450 W/cm2 for 50 or 60 seconds to simulate an aerocapture maneuver. The second laser exposure was at an irradiance of 115 W/cm2 for 100 seconds to simulate a planetary entry. Results from Rounds 1 and 2 of these screening tests are summarized.
Certain materials useful in space sensor construction were tested for their noncontaminating compatibility with channel electron multipliers. Gain profiles indicate that the materials tested do not adversely affect the lifetimes of the multipliers. These materials are, therefore, shown to be safe for use with channel electron multipliers in space instrumentation even for the most stringent long lifetime mission requirements. The tests indicate that the multipliers which are to be flown on an extended space mission will have adequate lifetimes to return satisfactory data throughout the entire mission.
Test methods require reference materials to standardize and maintain quality control. Various materials have been evaluated as possible reference materials, including a sample of bisphenol A polycarbonate without additives. Screening tests for relative toxicity under various experimental conditions were performed using male mice exposed to pyrolysis effluents over a 200-800 C temperature range. It was found that the bisphenol A polycarbonate served as a suitable reference material as it is available in large quantities, and does not significantly change with time.
Spacecraft reentry flight tests for determining performance of heat shields made of charring ablating material
The test facility presented herein uses a groundbased rocket combustor to test the durability of new ceramic composite and metallic materials in a rocket engine thermal environment. A gaseous H2/02 rocket combustor (essentially a ground-based rocket engine) is used to generate a high temperature/high heat flux environment to which advanced ceramic and/or metallic materials are exposed. These materials can either be an integral part of the combustor (nozzle, thrust chamber etc) or can be mounted downstream of the combustor in the combustor exhaust plume. The test materials can be uncooled, water cooled or cooled with gaseous hydrogen.
The average burn rates of several metals and alloys were determined at oxygen pressures between 3.45 and 68.91 MPa (500 and 10,000 psig) and ambient temperature. Several materials were tested at elevated sample temperatures. The test materials were fabricated into solid cylindrical rods and mounted vertically in the test chamber. A magnesium igniter was positioned at the bottom end of each test specimen to promote upward burn propagations. Nickel 200 and copper 102 could not be ignited at all oxygen pressures tested whereas Monel 400 appeared to ignite but quickly self-extinguished. The other materials tested burned the entire length of the test sample. Aluminum 6061 exhibited the fastest burn propagation rate. Inconel 718 burned slower than aluminum but faster than the stainless steels (types 304 and 316). Increasing oxygen pressure generally increased the burn propagation rate of the materials. Increasing the ambient temperature of the test specimens for several materials to approximately 850 K (1070 F) had little effect upon the ignition or burn properties of nickel 200 or Monel 400. Type 316 stainless steel exhibited an increase in its burn propagation rate at this higher temperature.
Development, and evaluation of thin film substrates containing sodium niobate capacitors, or sodium niobate dielectric material
Controlled environment chamber for physical tests of crushable materials encloses both the test specimen and the devices for performing the tests. The chamber may be stepped through a range of changing environment.
Tests were conducted to determine the damaging effects of rain erosion on optically transparent materials. The rotating arm test equipment used for the tests is described. Typical transparent materials such as those found in windshields, infrared windows, lasers, and television systems were tested. Nominal velocities of 400, 500, and 600 miles per hour and rainfall conditions of one inch per hour simulated rainfall were used in the tests. It was determined that an 80 percent reduction in laser transmittance can occur in plastics submitted to rain erosion. Significant results of the environmental tests are explained.
In a companion abstract, the "Mars Environmental Compatibility Assessment" (MECA) payload for Mars Surveyor Program 2001 (MSP 2001) is described in terms of its capabilities for addressing exobiology on Mars. Here we describe how the same payload elements perform in terms of gathering data about surface dust on the planet. An understanding of the origin and properties of dust is important to both human exploration and planetary geology. The MECA instrument is specifically designed for soil/dust investigations: it is a multifunctional laboratory equipped to assess particulate properties with wet chemistry, camera imagery, optical microscopy (potentially with LTV fluorescence capability), atomic force microscopy (AFM; potentially with mineral-discrimination capabilities), electrometry, active & passive external materials-test panels, mineral hardness testing, and electrostatic & magnetic materials testing. Additionally, evaluation of soil chemical and physical properties as a function of depth down to about 50 cm will be facilitated by the Lander/MECA robot arm on which the camera (RAC) and electrometer are mounted. Types of data being sought for the dust include: (1) general textural and grain-size characterization of the soil as a whole --for example, is the soil essentially dust with other components or is it a clast-supported material in which dust resides only in the clast interstices, (2) size frequency distribution for dust particles in the range 0.01 to 10.00 microns, (3) particle-shape distribution of the soil components and of the fine dust fraction in particular, (4) soil fabric such as grain clustering into clods, aggregates, and cemented/indurated grain amalgamations, as well as related porosity, cohesiveness, and other mechanical soil properties, (5) cohesive relationship that dust has to certain types of rocks and minerals as a clue to which soil materials may be prime hosts for dust "piggybacking", (6) particle, aggregate, and bulk soil electrostatic properties, (7) particle hardness, (8) particle magnetic properties, (9) bulk dust geochemistry (solubility, reactivity, ionic and mineral species). All of these quantities are needed in order for the human exploration program to make assessments of hazards on Mars, and to better enable the production on earth, of soil/dust simulants that can act as realistic test materials in terms of those properties that render dust a contaminant.Such properties include the small grain size that enables penetration of space-suit joints, mechanical interfaces and bearings, seals, etc., and presents difficulty for filtration systems. Size also plays a critical role in the potential for lung disease in long-term habitats. The properties of grain shape and hardness are important parameters in determining the abrasiveness of dust as it enters mechanical systems, or bombards helmet visors and habitat windows in dust-laden winds. Adhesive electrostatic and magnetic properties of dust will be prime causes of contamination of space suits and equipment. Contamination causes mechanical malfunction, tracking of dirt into habitats, "piggybacking" of toxins on dust into habitats, changes in albedo and efficiency of solar arrays and heat exchangers, and changes in electrical conductivity of suit surfaces and other materials that may have specific safety requirements regarding electrical conductivity. Other potentially hazardous properties of dust include the possibility of high solubility of some component grains (rendering them reactive), and toxicity of some materials --grains of superoxidants and heavy metals (there is always the slim, but not inconceivable possibility of biogenic components such as spores). Because Mars has no active surface aqueous regime, volcanic emissions, meteoritic debris, weathering products, and photochemical products of Mars have nowhere to go except reside in the surface; there are few mechanical or chemical (buffering) processes to remove the accumulation of eons. From a planetology perspective, there are many enigmatic issues relating to dust and the aeolian regime in general. MECA will be able to address many questions in this area. For example, if MECA determines a particular particle size distribution (size and sorting values), it will be possible to make inferences about the origin of the dust - - is it all aeolian, or a more primitive residue of weathering, volcanic emissions, and meteoritic gardening? Trenching with the Lander/MECA robot arm will enable local stratigraphy to be determined in terms of depositional rates, amounts and cyclicity in dust storms and/or local aeolian transport. Grain shape will betray the origin of the dust fragments as being the product of recent or ancient weathering, or the comminution products of aeolian transport --the dust-silt ratio might be a measure of aeolian comminution energy. Additional information is contained in the original.
The Long Duration Exposure Facility (LDEF) served as the ultimate laboratory to provide combined space environmental effects on materials. The LDEF structure and its 57 experiments contained an estimated 12,000 to 14,000 specimens of materials and materials processes. It not only provided information about the resistance of these materials to the space environment but gives us direction into future needs for spacecraft materials development and testing. This paper provides an overview of the materials effects observed on the satellite and suggests recommendations for the future work in space-qualified materials development and space environmental simulation.
The test program for the basic prepreg materials used in process development work and planned fabrication of the national transonic facility fan blade is presented. The basic prepreg materials and the design laminate are characterized at 89 K, room temperature, and 366 K. Characterization tests, test equipment, and test data are discussed. Material tests results in the warp direction are given for tensile, compressive, fatigue (tension-tension), interlaminar shear and thermal expansion.
For many years, the National Institute of Standards and Technology (NIST) produced reference materials for materials testing. One such reference material was intended for use with a guarded hot plate apparatus designed to meet the requirements of ASTM C177-97, "Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Guarded-Hot-Plate Apparatus." This apparatus can be used to test materials in various gaseous environments from atmospheric pressure to a vacuum. It allows the thermal transmission properties of insulating materials to be measured from just above ambient temperature down to temperatures below liquid hydrogen. However, NIST did not generate data below 77 K temperature for the reference material in question. This paper describes a test method used at NASA's Marshall Space Flight Center (MSFC) to optimize thermal conductivity measurements during the development of thermal protection systems. The test method extends the usability range of this reference material by generating data at temperatures lower than 77 K. Information provided by this test is discussed, as are the capabilities of the MSFC Hydrogen Test Facility, where advanced methods for materials testing are routinely developed and optimized in support of aerospace applications.
Promoted combustion testing of materials, Test 17 of NASA STD-6001, has been used to assess metal propensity to burn in oxygen rich environments. An igniter is used at the bottom end of a rod to promote ignition, and if combustion is sustained, the burning progresses from the bottom to the top of the rod. The physical mechanisms are very similar to the upward flammability test, Test 1 of NASA STD-6001. The differences are in the normal environmental range of pressures, oxygen content, and sample geometry. Upward flammability testing of organic materials can exhibit a significant transitional region between no burning to complete quasi-state burning. In this transitional region, the burn process exhibits a probabilistic nature. This transitional region has been identified for metals using the promoted combustion testing method at ambient initial temperatures. The work given here is focused on examining the transitional region and the quasi-steady burning region both at conventional ambient testing conditions and at elevated temperatures. A new heated promoted combustion facility and equipment at Marshall Space Flight Center have just been completed to provide the basic data regarding the metals operating temperature limits in contact with oxygen rich atmospheres at high pressures. Initial data have been obtained for Stainless Steel 304L, Stainless Steel 321, Haynes 214, and Inconel 718 at elevated temperatures in 100-percent oxygen atmospheres. These data along with an extended data set at ambient initial temperature test conditions are examined. The pressure boundaries of acceptable, non-burning usage is found to be lowered at elevated temperature.
The ablation mechanisms of stony meteorite material and a terrestrial analog were investigated at the Hypersonic Materials Environmental Test System (HyMETS) facility at NASA’s Langley Research Center. The primary analyte (Tamdakht-H5) and arc-jet test conditions were chosen to simulate the entry of an ordinary chondrite through the Earth’s mesosphere. Basalt was selected to compare the meteorite response against material with enhanced polymerization and an elevated concentration of volatile species. The initial ablation process for each material commences with the vaporization of volatile species and germination of a viscous melt layer on the stagnation surface. However, each material exhibited distinct mass loss mechanisms, with basalt recessing at twice the rate of Tamdakht. Inspection of high-speed video and chemical analysis of the post-test melt layer suggests the dominant mode of mass loss of Tamdakht is expressed through the vaporization of volatile compounds. Vaporization rates of Tamdakht are 18x higher than basalt under the most severe test conditions which provides enhanced thermal shielding. Furthermore, Tamdakht produces a relatively stable melt flow, as evidenced by perpetual growth at the sidewall and the exiguous detachment of molten material into the flow. The ablation mechanism of basalt is markedly different from Tamdakht and is governed by volatile species in the virgin material. The dominant mode of mass loss for basalt is attributed to the detachment of large sections of the stagnation surface near the edge radius. An additional but subordinate mode of mass loss is assigned to the removal of melt flow as it passes over the edge radius, where shear forces overcome the rheological properties of the molten matter. Finally, mechanistic details will be discussed in terms of designing future test campaigns, developing meteorite-based materials response models, and impacting the broader scope of the Asteroid Threat Assessment Project (ATAP).